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

• Transactions of Materials Processing
• /
• v.27 no.3
• /
• pp.165-170
• /
• 2018

In order to increase the lifetimes of cold forging dies, insert rings are generally used. In this study, an insert ring and shrunk ring of the flange upsetting die were designed for the cold forging of an automotive wheel nut. The Stress distribution occurring in the die during forging was simulated using a commercial finite element analyzing program. The effects of the fitting interference and inclined angle of the insert ring on the compressive stress of the die inside were also investigated. The simulated data were compared with the real lifetimes of the forging dies. The maximum compressive stress acting on the edge of a forging die should have the most influence on die lifetime, an idea which could help develop the die design with the longest lifetime. The design of the most optimal forging die with the longest lifetime is made possible by analyzing the maximum inner pressure and principal stress between the shrunk ring and insert ring.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2002.05a
• /
• pp.112-116
• /
• 2002

In cold forging, the elastic behavior of the die has a direct influence on the accuracy of the forging part. And the die dimension is continuously changed during the loading, unloading, and ejecting stage. In this paper, we evaluated the elastic deflections of cold forging die during loading, unloading, and ejecting stage. Uni-axial strain gauges are used to measure elastic strain of die during each forging stage. Strain gauges are attached on the surface of die. A commercial F.E.M code, DEFORM-2D$\^$TM/ is used to predict elastic strain of die. Two method of F.E.M. analysis are used to compare with measured and calculated elastic strain. One is to regard the die as rigid body over forging cycle. And then, the die sass is analyzed by loading the die with pressure from the forging part. The other is to regard the die as elastic body from forging cycle. The elastic strain of die is calculated and the die is elastically deformed at each strop. The calculated results under the elastic die assumption are well agreed with experimental data using strain gauges.

• Transactions of Materials Processing
• /
• v.26 no.3
• /
• pp.156-161
• /
• 2017

In this study, the reason of die fracture occurring in hot forging of an aluminum fixed scroll was studied, based on experiments and finite element predictions. The material is assumed to be rigid-viscoplastic, and the die is rigid for the finite element predictions. The stress in the tension at the wrap root is known to cause brittle fracture, and the increase in the tensile stress is owing to the unbalanced filling of material into the die cavities between both sides of the warp. Based on the empirical and numerical achievements, the effects of geometrical parameters of the material on the die fracture were examined to find practical measures for elongated die life. It has been shown from the parametric study that the material with the optimized trapezoidal cross-section, which can be easily made during cutting or the optimized cylindrical billet with its eccentric placement in the die cavity, can considerably reduce the magnitude of the tensile stress around the die corner fractured, indicating that economical manufacturing with reduced number of stages and elongated die life can be realized at once using the optimized practical initial material.

• Transactions of Materials Processing
• /
• v.12 no.4
• /
• pp.277-283
• /
• 2003

In a closed-die forging process, blocker has been used to fill and distribute metal well in finisher die. Generally, the blocker shape was determined by an expert with many experiences. However, the manual blocker design process takes much time and efforts, so various automatic methods for the blocker design process have been suggested for the last three decades. The method with filtering in FFT (Fast Fourier Transform) for the blocker design provides general solution than other methods. But. due to the properties of FFT in time-frequency domain, this method has some drawbacks such as long calculation time, difficulty of local control and additional boundary process after filtering. In this study. DWT (Discrete Wavelet Transform), which is more flexible and is more wildly used than FFT, is applied to the blocker design. The method with filtering in DWT is very proper to design blocker in both 2-D and 3-D shapes. To verify the efficiency of this method, blockers of some models are designed and the results show that blocker design with DWT is effective for the blocker designs.

• Transactions of Materials Processing
• /
• v.19 no.6
• /
• pp.378-386
• /
• 2010

Nowadays there has been great interest in using heat treated cast material for press dies due to several advantages like reduction in die production costs. However, in hot press forming processes H13 forged tool steel is mostly used. Cooling performance of dies in hot press forming processes is considered as an important factor of study and also the IHTC parameter between cast material die and sheet metal should be considered as an essential. In the present study, the IHTC was calculated for the sheet metal in the hot press forming process with cast and forged material dies. The temperature measurements were performed for the sheet metal, casting and forged material dies by applying various contact pressure in hot press forming. IHTC was calculated and studied by adopting the inverse heat convection method in DEFORM-2D. Each IHTC was considered as a function of contact time and contact pressure. The experimental data were compared with calculated data obtained from the proposed equation and references.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.15 no.2
• /
• pp.653-659
• /
• 2014

Computer simulation has been performed to optimize cold forging process of automotive LPI fuel filter housing. A mold and the test product have been manufactured considering the strain and load distribution during the cold forging process. Also, fuel flow simulation has been performed to analyze flow characteristics of existing model and new model. Simulation result shows that two models have equivalent pressure drop. Compared with the mass of existing product, raw material reduction of 16 g and 30.5 g has been achieved from the upper and lower housing, respectively. Total mass reduction of the new housing was 46.5 g. Leak test and internal pressure test have been performed to verify the safety standard and test results were satisfactory.

• Transactions of Materials Processing
• /
• v.29 no.6
• /
• pp.362-369
• /
• 2020

In this study, elastoplastic finite element analysis with multi-body treatment was used to elucidate the mechanical phenomena occurring from pre-stressing of die-system. A finite element analysis model with detailed conditions is proposed. The effects of die pre-stressing slope on the circumferential components of the pre-stressed die inserts were evaluated. The role of tight fitting between the supporter and die case was also emphasized because it has a significant effect on the undesirable change in the target slope of machined inner surface of the die case around the die insert. The two mechanical problems include the one between die-insert and die case and the other between supporter and die case, and their correlation is minimized to establish the optimum design in the die structural design stage because it cannot be quantitatively controlled owing to various factors affecting the die structural behavior during die pre-stressing.

• Transactions of Materials Processing
• /
• v.28 no.3
• /
• pp.115-122
• /
• 2019

In this paper, finite element analysis of an automatic five-stage precision cold forging process of a yoke, a steering part of a passenger's car, is conducted with emphasis on spring back analysis at the yoke-forming stage and its experimental verification is subsequently made. An elastoplastic finite element method with MINI-element technique employed for the analysis of the entire process is explained. There is emphasis that the thin film of material formed between the punch and die in the stage may result to some errors especially in elastoplastic finite element analysis of spring back due to frequent remeshing. The numerical robustness of the spring back analysis in regards to remeshing is hence shown first through investigation into its effect on the predicted spring back. Experimental measurement of displacement due to spring back is carried out for comparison with the predicted results, and they are in a qualitative agreement with each other.

• Transactions of Materials Processing
• /
• v.32 no.1
• /
• pp.5-11
• /
• 2023

The aim of this study is to manufacture an aluminum pipe yoke of automotive steering system for lightweight. In a multistage cold forging process for aluminum pipe yoke, the surface defects frequently occur due to excessive deformation or friction during extrusion process for forming hollow pipe part. It is import to reduce the friction between the material and the forging die. This study investigated a multistage forging process with sliding die to reduce friction for aluminum pipe yoke. After evaluating by FE analysis, the forging experiment with the sliding die was carried out. As a result, it was possible to manufacture a sound aluminum pipe yoke.