• Transactions of Materials Processing
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• v.19 no.7
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• pp.399-404
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• 2010

We propose an analysis model for simulating the detailed procedure of pore closing in open die forging of shafts. In the analysis model, an artificial symmetric plane is used, on which initial pores are located to be traced. The analysis model is employed to carry out three-dimensional simulation of pore closing in shaft free forging by both conventional free forging press and radial forging machine. With this result, two typical types of free forging equipment for manufacture of shafts are compared in detail. It has shown that the radial forging machine is much superior to the conventional open die forging press especially in pore closing under high hydrostatic pressure with sound strain.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.5
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• pp.1166-1180
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• 1990

The study is concerned with the two-dimensional thermo-viscoplastic finite element analysis for radial forging as an incremental forging process. The deformation and temperature distribution of the workpiece during radial forging are studied. The analysis of deformation and the analysis of heat transfer are carried out for simple upsetting of cylinder by decoupling the above two analyses. A method of treatment for heat transfer through the contact region between the die and the workpiece is suggested, in which remeshing of the die elements is not necessary. Radial forging of a mild steel cylinder at the elevated temperature is subjected to the decoupled finite element analysis as well as to the experiment. The computed results in deformation, load and temperature distribution are found to be in good agreement with the experimental observations. As an example of viscoplastic decoupled analysis of hot radial forging, forging of a square section into a circular section is treated. The stresses, strains, strain rates and temperature distribution are computed by superposing material properties as the workpiece is rotated and forged incrementally. It was been thus shown that proposed method of analysis can be effectively applied to the hot radial forging processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.95-98
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• 2005

Shafts having asymmetry or odd number of symmetry in the cross-section can not be simply manufactured by conventional incremental radial forging. In order to manufacture such shafts, the new concept of incremental forging with one punch and a flexible fixture is developed by suggesting a flexible fixture, instead of two opposed punches used in radial forging, so that the flexible fixture only supports the workpiece while the punch is moving during forming. A new flexible fixture is designed using the steel shots and vacuum technology. An equilateral triangular cross-section is selected as the sample shape to be manufactured by the proposed manufacturing method. The desired triangular cross-sectional shaft is manufactured with the errors of $3.0\%$.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.197-198
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• 2008

The forging process produces complicated and designed components in a die at high productivity for mass production and minimizes the machining amount for favorable material utilization; the forging products used at highly stressed sections are well accepted at a wide range of industry such as automobile, aerospace, electric appliance and et cetera. Accordingly, recent R&D activities have been emphasized on improvement of forging die-life and near net shaping technology for cost effectiveness and better performance. Usually closing and consolidation of internal void defects in a ingot is a vital matter when utilized as large forged products. It is important to develop cogging process for improvement of internal soundness without a void defect and cost reduction by solid forging alone with limited press capacity. For experiments of cogging process, hydraulic press with a capacity of 800 ton was used together with a small manipulator which was made for rotation and overlapping of a billet. Size of a void was categorized into two types; ${\phi}$ 6.0 mm and ${\phi}$ 9.0 mm to investigate the change of closing and consolidation of void defects existed in the large ingot during the cogging process. In addition for forming experiment of piston grown air drop hammer with a capacity of 16 ton was used. The experiment with piston crown was carried out to show the formability and void closing status. In this paper systematic configuration for closing process of void defects were expressed based on this experiment results in the cogging process. Also forging defects through forming process for piston crown was improved using the experiment results and FE analysis. Consequently this paper deals with the effect of radial parameters in cogging process on a void closure far large forged products and formability of piston crown.

• Transactions of Materials Processing
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• v.8 no.6
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• pp.604-611
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• 1999

This paper is concerned with the family of parts that generally feature a central hub with radial protrusions. As opposed to conventional forward and backward extrusion, in which the material flows in a direction parallel to that of the punch or die motion, the material flows perpendicular to the punch motion in radial extrusion. Three variants of radial extrusion of a collar or flange are investigated. Case I involves forcing a cylindrical billet against a flat die, Case II involves deformation against a stationary punch recessed in the lower die, and Case III involves both the upper and lower punches moving together toward the center of the billet. Extensive simulational work is performed with each case to see the process conditions in terms of forging load, balanced and symmetrical flow in the flange. Also, the effect of the gap size and die corner radii to the material flow are investigated. In this study, the forming characteristics of radial extrusion will be considered by comparing the forces, shapes etc. The design factors during radial extrusion are investigated by the rigid-plastic FEM simulation.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 1999.06a
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• pp.80-85
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• 1999

Residual stress in the forged products directly affects material stability, resistance to deformation, accuracy, and fatigue life of products. It is very important to study the residual stress distributions in forged products and to monitor operating conditions for the minimum tensile or maximum compressive residual stresses. As a way to study the residual stress formation due to radial forging, a three dimensional theoretical model was developed using ANSYS finite element program. Using the developed model, residual stress distributions in forged product were calculated and selected results were compared with the published experimental data to verify the effectiveness of the developed model.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.67-70
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• 2008

This paper deals with the effect of radial parameters in cogging process such as reduction in height (Rh) and rotational angle ($\theta$) of a billet on a void closure for large forged products. Usually closing and consolidation of internal void defects in a ingot is a vital matter when utilized as large forged products, using a press with limited capacity and the sizes of the ingots becoming larger. Consequently, it is important to develop cogging process for improvement of internal soundness without a void defect and cost reduction by solid forging alone with limited press capacity. For experiments of cogging process, hydraulic press with a capacity of 800 ton was used together with a small manipulator which was made for rotation and overlapping of a billet. Size of a void was categorized into two types; $\emptyset$ 6.0 mm and $\emptyset$ 9.0 mm to investigate the change of closing and consolidation of void defects existed in the large ingot during the cogging process. Also open void and closed void in the ingot were tackled to show the differentiation of closing process of internal voids with respect to void sizes. In this paper systematic configuration for closing process of void defects were expressed based on this experiment results in the cogging process.

• Journal of the Korean Society for Precision Engineering
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• v.9 no.3
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• pp.83-101
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• 1992

A systematic method of remeshing is required due to severe mesh distortion after some finite deformation in the finite element analysis of practical forging processes. In order to cope with the problem of mesh degeneracy during deformation, the proper design of meshes plays an improtant role in the analysis. In so-called "Modular Remeshing", the physical characteristics of metal flow and geometric characteristics are incorporated in "Module", which can be applied to the mesh design for a certain mode of deformation in so far as the topology of deforming region remains the same. For the purpose of more effective and systematic use of the modular remeshing scheme, an expert system has been developed in the framework of the proposed remeshing schemel. In oredr to show the effectiveness of the method, the rib-web type forging with axial relief or radial relief and spike forging are simulated. It has been thus shown that the proposed method of automatic remeshing by using modular remeshing and expert system can be futher extended and applied to various forging problems with complicated geometrical configurations.ical configurations.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.233-235
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• 2001

Residual stress in the forged parts affects the resistance to mechanical failure, dimensional uniformity, and the service life of the parts. In order to elucidate the development of residual stress in open-die forging process, elasto-plastic finite element analysis was implemented to radial forging process. Super duplex stainless steel SAF 2507 was selected as workpiece material and a series of mechanical tests followed by numerical compensation to deformation heating was conducted to obtain necessary flow data. The residual stress distributions were calculated using commercial 3-D FEM code and the effects of process design were evaluated from selected results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.10a
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• pp.204-208
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• 2001

Position control of the electro-hydraulic servo indexing system in a flexible forging machine was investigated Flexible forging machine forges an axial type workpiece in the radial direction as well as in the axial direction. The role of the indexing system is to rotate a workpiece fast and accurately to a desired position for continuous shaping. Since the inertia of a workpiece changes during each forging step, a control technique which is robust to inertia variation should be adopted to the position control of the workpiece. In this study, time delayed control technique is applied to the servo system. Time delayed control method does not depend on estimation of specific parameters. Rather, it depends on the direct estimation of a function representing the effect of uncertainties. Direct estimation is accomplished using time delay and the gathered information is used to cancel the unknown dynamics is accomplished using disturbances simultaneously. Experimental result show that the time delayed controller is robust to inertia variation of the load, and satisfactory performance on the sposition accuracy is obtained compared to the contentional feedback control.