• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.4
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• pp.876-886
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• 1994

Process design in superplastic forming to produce a Nickel-base jet engine disk has been carried out using the rigid-viscoplastic finite element method. This study aims at deriving systematic procedures in forging of superalloy engine disk, and develops a simple scheme to control strainrate within a range of superplastic deformation during the forging operation. The new process, a pancake type preform being used, is designed to have less manufacturing time, and more even distribution of effective strain in the final product, while the conventional superplastic forging of an engine disk has been produced from a cylindrical billet. The jet engine company, Pratt & Whitney, provided the basic information on the manufacturing process of superplastic forging of a jet engine disk.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.4
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• pp.69-74
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• 2001

Powder forging technology has been introduced to manufacture the parts for vehicles. This paper describes the process conditions for the powder forging of aluminium also piston for vehicles including the determination of composition of aluminum alloy by experiment, preform design by FEM simulation, coed compaction of aluminum alloy powder, sintering of preform, and the experiment of powder forging. The mechanical properties such as hardness, tensile strength, and elongation of the farmed piston were invested and compared with casted piston and forged piston. The tensile strength and hardness of the piston formed by powder forging technology were much more excellent than other pistons.

• Journal of Powder Materials
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• v.2 no.1
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• pp.19-28
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• 1995

Powder forging is a combined technology of powder metallurgy and precision hot forging. Recently, the technology is developing rapidly because of its economic merits, especially in automotive part manufacturing. In the present study, the finite element technique was developed to predict density variation during P/M forging and the technique was applied to analysis of forging of a P/M connecting rod. Although deformation mode of the connecting rod was quite complex, several sections were selected and analyzed under an assumption of asymmetric or plane strain deformation. It was found that some modifications were necessary on the cross section of the beam portion. Therefore, the cross section was modified repeatedly until a satisfactory result of the analysis was obtained. On the other hand, no modifications were necessary in the ring and the pin portions. It is anticipated that the developed technique can be used to optimize preform design and manufacturing processes in P/M forging, which are highly critical to produce successful products in practice.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.126-129
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• 1998

Proper design of blocker dies is one of the most important aspect of impression and closed-die forging to achieve adequate metal distribution. Determination of the blocker configuration is a very difficult task and is art in itself, requiring skills achieved only by years of extensive experience. To save the cost and time of blocker design, many methods using computer were proposed. In this research, low pass filter method proposed by Oh etc. was applied to blocker die design of spoiler support, part of aircraft and plasticine model experiment of closed die forging of spoiler support was accomplished to verify the validity of the blocker designed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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• pp.130-136
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• 2022

Reducing production costs through net-shaped cold forging is an important aspect in the automobile industry. In this study, we intend to produce a net-shaped electronic parking brake (EPB) serration gear for automobiles, using multi-stage cold forging. These serrations are then assembled to the reduction gear of an EPB actuator. The forging process of the serrations and the cold forging design were verified through finite element analysis (FEA) in order to evaluate metal flow. The forging machine was selected by checking the load using FEA. Based on the FEA results, molds were designed, and parts were made using multi-stage cold forging to produce a net-shaped serration gear.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.3
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• pp.9-17
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• 2000

The use of ceramic inserts in steel forging tools offers significant technical and economic advantages over other materi-als of manufacture. These potential benefits can however only be realised by optimal design of the tools so that the ceramic insert are not subjected to stresses that led to their premature failure. In this paper the data on loading of the tools is determined from a commercial forging simulation package as the contact stress distribution on the die-workpiece interface and as temperature distributions in the die. This data can be processed as load input data for a finite-element die-stress analysis. Process simulation and stress analysis are thus combined during the design and a data exchange program has been developed that enables optimal design of the dies taking into account the elastic detections generated in shrink fitting the die inserts and that caused by the stresses generated in the forging process. The stress analysis of the dies is used to determine the stress conditions on the ceramic insert by considering contact and interference effects under both mechanical and thermal loads. Simulation results have been validated as a result of experimental investigation. Laboratory tests on ceramic insert dies have verified the superior performance of the Zirconia and Silicon Nitride ceramic insert in order to prolong maintenance life.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.13 no.5
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• pp.1990-1995
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• 2012

This paper presents design methodology to determine the design parameters that affect the manufacture of aluminum forging piston using the FE simulation and the Taguchi method. Maximum forging load is used as the objective function, and preform, material temperature and draft angle are selected as the design parameters. Their combinations are implemented by orthogonal array, and forging load is evaluated through the simulation. From the analytic results of design parameters to minimize the load using signal to noise ratio, their optimal combinations are proposed. The proposed design methodology will be able to help in selecting proper preform among preforms and to be used in determining the optimal combination of the parameters in metal forming process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.399-402
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• 2006

The outer race of CV(constant velocity) joint is an important load-supporting automotive part, which transmits torque between the transmission gear box and driving wheel. The outer race is difficult to forge because its shape is very complicated and the required dimensional tolerances are very small. Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability. Therefore, multistage forging may be advantageous to produce complex shaped parts. In order to build a multistage forging system, it is necessary to characterize mechanical properties in response to system design parameters such as temperature, forging speed and reduction. For the analysis of formability of multistage forging process, finite element method(FEM) has been used for the process analysis. As a model case, a constant velocity (CV) joint forging process is analyzed by FEM, since CV joint has a complex shape and also its required dimensional tolerances are very tight. The data acquired by FEM is compared with operational forging data obtained from an industrial production line. Based on this comparative analysis, multistage forging process for CV joints is proposed.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.88-94
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• 2014

The under-drive brake piston is an essential part in the automatic transmissions of automobiles. This component is manufactured by forging after blanking from S55C plate with a thickness of 6mm. It is difficult to design the plate forging process using a thick plate approach since there will be limited material flow as well as large press loads. Furthermore, the under-drive brake piston has a complex shape with a right angle step, which often results in die unfill and abrupt increase in press load. To overcome these obstacles, a separate die for filling material sufficiently to the corner of the right angle step is proposed. However, this approach induces an uncontrolled workpiece surface between the dies, resulting in flash. This excess flash degrades the tool life in the final machining after cold forging as well as increases the cycle time to obtain the net-shape of the part. In the current study, we propose an optimum process design using a conventional die shaped with the benefit of finite element analysis. This approach enhanced the process efficiency without sacrificing the dimensional accuracy in the forged part. As the result, the optimum plate forging process was done with a two stage die, which reduces weight of by 6% compared with previous process for the under-drive brake piston.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.9
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• pp.93-99
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• 2020

Recently, as the weight reduction of vehicles has been actively progressed, parts developed using aluminum 60XX series from existing steel materials are increasing. In this paper, the bushing used for the front frame rail, which is one of the parts for fixing engines and other parts in automobiles, was changed to an aluminum material of the Al60XX series, and it was intended to be produced by applying of cold forging method. The bushing is a part that secures the engine frame, and in order to produce it by cold forging, the molding limit is predicted through process design, and a multi-stage process is designed through finite element analysis. In addition, in order to verify the feasibility of the designed forging process, the limits of the multi-step process were verified based on the Cockcroft Latham theory, and the crack and overlap of the actual forging work were predicted and improved.