2011 pp.

1 2 2 #

Finite Element Prediction of Air Pocket Phenomenon in a Hot

Forging Process

B. S. Kim, D. I. Roh, K. R. Kim, M. S. Joun

Abstract
In this paper, a three-stage pancake-shape hot forging process is simulated with emphasis on prediction of under-filling

defects due to air pocketing phenomena in the cavities enclosed by material, dies or tools and plane of symmetry. The

basic approach is introduced to deal with air pocketing phenomena. The volumetric strain of each cavity is traced when

the air pocket has no air hole and its pressure that is a function of the volumetric strain and maximum normal stresses of

the neighboring contact interfaces is exerted onto the surface of material inside the air pocket. The presented approach is

applied to a three-stage plate forging process in which the air pocketing phenomena can be sensitive to the plastic

deformation of material. Predictions are compared with experiments, showing that they are in excellent agreement with

each other.

Key Words : Hot Forging (), Air Pocket (), Metal flow line ()

1.

, . ,

. (air
pocketing) . .

98
 2011 pp.

Hwang [3] Koo [4]

Joun [5]

1.
2.
# : /
E-mail: msjoun@gnu.ac.kr

99

Vj j
.

DV j .

e vcj = e vcj -1 - De vj (2)

2.

Fig. 1 2
e vcj j
.

, 2 .

. .

2 .

2 . (a) Symmetric axis case occurring in an axi-symmetric

forging

.
j De v j

V j +DV j dV DV j
De vj = = ln(1 + ) (1)
Vj V Vj (b) Schematic diagram of the air pocketing problem.

100
 Fig. 1 Schematic diagram of the air pocketing
problem

pair

. ,
- : Fig. 3
pair = B e vcj when B e vcj < pmp (3) - : Coulomb friction (Coefficient of
pair = pmax when B e vcj pmp (4) Coulomb friction, m = 0.2 )

, B , pmp

Fig. 2 Process design of the test example

3. Fig. 3 Flow stress information.

. Fig. 2

, . Fig.

70.0mm, 110.0mm . 4

101
 .

125 MPa ,

Fig 5 Fig. 5 Metal flow lines at the final stroke of the test

. Fig. 6 example

.
Fig. 6(a) ,

Stage 1

. Fig. 5

, Fig. 6(b)

, Fig. 5

. Stage 2

Stage 3

(a) Without air pocketing (b) With air pocketing

Fig. 6 Comparison of the results of the two

predictions

4.

Fig. 4 Variation of under filling defect size with bulk

modulus of elasticity

102
 . Vol.19, pp. 447 ~ 451.

[3]

S. J. Hwang, W. G. Park, C. Kim, S. W. Oh, N. Y. Cho,

2006, Flow analysis of the air pocket in draw die.

. Proceedings of The 4th National Congress on Fluids

Engineering, Korea, pp. 345~348.

[4]

. T. K. Koo, S. J. Hwang, W. G. Park, S. W. Oh, 2008,

AFDEX[8] Prediction of air pocket pressure in draw die during

. stamping process, Transactions of KSAE, Vol. 16,

pp. 10~18.

. [5]

J. G. Eom, J. H. Chung, B. S. Kim, S. W. Lee, M. S.

. Joun, 2012, Finite Element Analysis of a Plate

Forging Considering Air Pocketing Phenomena,

15th International Conference on Advances in

Materials & Processing Technologies, Australia

[6]

C. H. Lee, S. Kobayashi, 1973, New solution to rigid

. plastic deformation problems using a matrix

method, Trans. ASME, J. Eng. Ind., Vol. 95, pp.

865~873.

[7]
[1] M. C. Lee, S. H. Chung, S. M. Jang, M. S. Joun, 2009,

T. Nakano, 2012, Evolution of key technologies of plate Three-dimensional simulation of forging using

forging, The 297th JSTP Symposium on Metal tetrahedral and hexahedral elements, Finite

Forming, Japan Elements in Analysis and Design, Vol. 45, pp.

[2] 865~873.

J. S. Kim, K. S. Kim, S. H. Shim, J. G. Eom, M. J. Joun, [8]

2010, Die system for avoiding thickness reduction M. S. Joun, M. C. Lee, J. G. Eom, 2011, Intelligent

along the bent corner in warm plate forging of an metal forming simulation, Proceedings of the ASME

axle housing, Transactions of Materials Processing, 2011 international Manufacturing Science and

103
Engineering Conference MSEC2011, USA

104