• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.5
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• pp.582-588
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• 2011

This study was aimed at the design of the dies for the unified shaft joint using the computer simulation to shorten the period of production, on the basis of the process planning which was designed by the field experts. In the computer simulation, 'Deform-3d' and 'Eesy-DieOpt' have been used, which are the commercial process analysis and die design program. Through the process analysis, we could know the propriety of the forming process, the inner pressure of the die and the suitable fitting pressure between the insert and the sleeve which was not showing any positive tangential stresses in the insert. Through the simulation of die design, we could know the number of the stress ring, the diameter ratios, the stresses of the die, the shrink fitting tolerance and temperature in the condition of the already determined maximum outer die diameter of the multi-stage former. The validity of the die design using the computer simulation was analyzed by the experiments and the results were satisfactory. As the results of this study, the new and easy die design system for multi-forging has been developed.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.11
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• pp.223-229
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• 2016

In this study, a cold forging process was developed for the roller tappet housing of an engine valvetrain system. A tappet sample was manufactured and subjected to an endurance test. The material properties were obtained from a compression test, and forging analysis was carried out to design a forging process using a commercial program, Deform-3D. The forging process was set up based on the analysis results, and a die set and sample tappet housing were manufactured. To evaluate the sample, the dimensional accuracy, surface roughness, parallelism, and concentricity were measured and confirmed. To evaluate the actuation and durability, a special test rig was developed to simulate the valvetrain system of the engine. An actuation test was performed based on the idle speed of a general diesel engine, and an endurance test was done based on the maximum speed. The results show minor wear of 0.002 mm. The developed test rig will be used to evaluate the actuation and durability of other valvetrain parts.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.2
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• pp.594-603
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• 1996

It has been known that the life time of cold forging dies is shorten by the cracks and wear produced during the operation. Thus it is required to mak the same new one too often, At this time of making new ont the cutting work and electical discharge machining were mormally used. But the precision of product is declined in every times of making the mew dies due to the diffefence in dimensional accuracy arised from the electical discharge machining. Especially it can't meet the delivery date because the production was delayed for making another die. Furthemore it has the problem of increasing the production cost. Therfore inthis study we tried to solve these problems using the hobbing method instead of electical discharge machining.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.124-127
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• 2009

In this paper, a longitudinal die insert fracture which occurred during cold forging of a high strength ball-stud with a sound die design nearly optimized empirically for relatively low strength material of SCM435 is introduced and the reason is revealed. A comparative study between SCM435 and ESW105 is quantitatively made using a thermoelastic finite element method for die structural analysis coupled with a forging simulator theoretically based on a rigid-plastic finite element method. It has been shown that the longitudinal die insert fracture caused from non-optimized value of shrink fit, emphasizing that the die optimal design is inevitable for cold forging of high strength materials.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.377-380
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• 2000

The dimensional accuracy of the cold forged part is depended on the elastic characteristics of the die. To obtain the high stiffness of the prestressed die, the first stress ring of the tungsten carbide material is considered. For the design, Lam 's equation is used. The design of the prestressed die has been compared with the conventional that. For the comparison, the FE-analysis using ANSYS has been performed. The results indicate that the prestressed die with the high stiffness can be obtained by the using the high stiffness material as the first stress ring.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.12
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• pp.145-151
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• 2001

The dimensional accuracy of the cold forged part is depended on the elastic characteristics of the die. To increase the stiffness of the prestressed die, the first stress ring of the tungsten carbide alloy (WC) is considered. For the design, Lame's equation is used. Diameter ratios and interferences have been determinated by maximum inner pressure without yielding of materials. The design of the prestressed die has been compared with the conventional one. For the comparison, the FE-analysis using ANSYS has been performed. The results indicate that the prestressed die with the high stiffness can be obtained by the using the high stiffness material as the first stress ring.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.253-254
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• 2010

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.249-250
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• 2010

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.101-105
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• 2000

In cold forging die the shrink fitting is generally used to decrease stress and increase die life. In this paper we have studied about the effect of fitting type, When the die insert is splitted into several pieces the maximum stress could be decreased as much as 50~70% The fitting angle could be selected to minimize the maximum stress and the variation of stress on loading and unloading, . In F, E.M result in case 3。 fitting angle the maximum and variation of stress may be minimized.

• Transactions of Materials Processing
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• v.9 no.2
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• pp.159-164
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• 2000

In this paper, a computer simulation technique for the forging process having a floating die is presented. The penalty rigid-plastic finite element method is employed together with an iteratively force-balancing method, in which the convergence is achieved when the floating die part is in force equilibrium within the user-specified tolerance. The force balance is controled by adjusting the velocity of the floating die in an automatic manner. An application example of a three-stage cold forging process is given.