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반경단조 공법을 이용한 사각봉재 제조공정의 최적 금형설계
장성민(S. M. Jang),김홍태(H. T. Kim),장시진(S. J. Jang),전만수(M. S. Joun),문호근(H. K. Moon) 한국소성가공학회 2012 한국소성가공학회 학술대회 논문집 Vol.2012 No.5
In conventional open die forging press, the material is formed by up and down motion of punch and thus the longitudinal elongation per stroke is relatively small, resulting in long manufacturing time. In addition, the center of material is exposed to decisive defects generated during cogging due to Mannesmann’s effect, that is, repeated deformation in compression after tension. To the contrary, four punches or dies in radial forging press the material in four perpendicular directions at the same time, which results in better quality as well as short manufacturing time. In the paper, the manufacturing process of a square bar using radial forging press is simulated to optimize die design and a set of optimized dies are given
유한요소해석을 통한 자유단조 중의 대형 단조품의 피어싱 공정용 금형 형상 최적화
장성민(S. M. Jang),김홍태(H. T. Kim),문호근(H. K. Moon),전만수(M. S. Joun) 한국소성가공학회 2013 한국소성가공학회 학술대회 논문집 Vol.2013 No.10
In this paper an optimized punch shape for piercing process of large forgings in open die forging is presented, which is obtained by finite element prediction of four possible designs. The optimized die shape is determined in terms of forming load and material loss. Based on the predictions of the four possible punch shapes, a new optimized punch shape is proposed, which has two tapered lateral surfaces.
대형 축의 자유단조에서 기공압착 관점에서 일반 프레스와 회전단조 프레스의 비교 연구
장성민(S. M. Jang),엄재근(J. G. Eom),김성현(S. H. Kim),이민철(M. C. Lee),전만수(M.S.Joun) 한국소성가공학회 2010 한국소성가공학회 학술대회 논문집 Vol.2010 No.5
We propose an analysis model of simulating the detailed procedure of pore closing in free forging of large shafts. In the analysis model, an artificial symmetric plane is used, on which initial pores are initially 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 large shafts are compared in detail. It has shown that the radial forging machine is much superior to the conventional free forging press especially in pore closing under high hydrostatic pressure with sound strain.
대형크랭크샤프트 해머단조공정의 시뮬레이션 및 실험적 검증
장성민(S. M. Jang),김성현(S. H. Kim),이민철(M. C. Lee),제갈영진(Y. J. Jegal),박태현(T. H. Park),조범제(B. J. Cho),전만수(M. S. Joun) 한국소성가공학회 2010 한국소성가공학회 학술대회 논문집 Vol.2010 No.5
In this paper, non-isothermal analysis of hammer forging process for a large crankshaft is conducted. A simple and computationally efficient approach to non-isothermal three-dimensional hot forging simulation, theoretically based on a rigid-thermoviscoplastic finite element method, is employed. In the approach, it is assumed that the temperatures of dies are increased at the same ratio as the workpiece temperature decreases. Hot forging of a large crankshaft is simulated using AFDEX 3D and the simulated result is compared with the actually forged one in detail. It has been verified that the predictions are in good agreement with the experiments. The successful simulation and development of a large crankshaft by the hammer forging technology will contribute to opening a new area of hammer forging application and to enhancing competitiveness of national machinery industries especially including ship part industries.