• Title/Summary/Keyword: 단조금형 설계

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Die Design of Semi-Solid Forging by Computer Simulation and their Experimental Investigation (Computer Simulation에 의한 Semi-Solid 단조금형의 설계 및 실험적 검정)

  • Seo P. K.;Lee D. H.;Kang C. G.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2000.10a
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    • pp.185-190
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    • 2000
  • Die design by computer simulation has some advantages compared with the conventional method which has performed by designer's experiences and trials and errors. The die filling and solidification process of thixoforming process were simulated by MAGMAsoft/thixo module. First of all, thixoforming die design was applied to previously geometry shape. The value of pressure distribution shows high and uniform as the gate diameter is 18mm. Designed gating system considering the deformation of die and product was suggested by the filling simulation. Gate velocity(7.25m/s) of designed gating system shows that propriety to semi-solid metal working process and CAE results were in good agreement with experimental results.

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Die design on the Precision Cold Forging of Spur Gear (평기어의 정밀 냉간단조 금형설계)

  • 권혁홍
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 1998.10a
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    • pp.242-247
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    • 1998
  • The conventional closed-die forging processes had been applied to forging of the spur gears. But this type process requires high pressure. The commercial finite element analysis code ANSYS for the stress and elastic deformation of non-axisymmetric die was adopted in this study. In the non-axisymmetric die such as gear forging, maximum stresses were imposed on the tip of the gear tooth. When the stress exceeds yield strength of insert die, many approaches were attemped to prevent the die failure. Good shaped products are forged successfully. This type process could by used as an advanced technique to replace conventional hobbing process of gear.

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The Effect of Die Design and Process Condition in Precision Forging for AI7075 Alloy(l) (AI7075합금의 정밀단조시 금형설계와 단조조건의 영향(l)-실험과 상계해석을 중심으로-)

  • 이영선;이정환;정형식;이상용;이동원
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1996.10a
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    • pp.105-112
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    • 1996
  • Aluminium alloy have been used extensively as forging materials for aircraft components due to their high specific strength and corrosion resistance. A large portions of these materials are used as airframe components consisted of various combination of such Rib-Web structure. But the problem of high forging pressure and defect which were caused by narrow Rib thickness prevented from the favorable developments and laboratory scaled trials. In this study, optimization of forging variables such as corner radius and temperature in Rib-Wed structure were established. The 2 mm of corner radius minimized the forging pressure to get the fixed Rib height, which well coincided with theoretical result according to Upper-Bound analysis. And optimum workpiece temperature was below 450$^{\circ}C$ in consideration of grain growth and forging defects by local melting.

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The Effect of Die Design and Process Condition in Precision Forging for AI7075 (ll) (AI7075합금의 정밀단조시 금형설계와 단조조건의 영향(ll) -유한요소해석을 중심으로-)

  • 이영선;이정환;이상용
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1996.10a
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    • pp.113-121
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    • 1996
  • AI7075 alloy has been used for aircraft components since it has the advantage of high strength, high toughness, and high corrosion resistance. Many airframe components consist of various combinations of rib-web structure. In this study, various process paramenters such as die design, lubricant, ram speed, forging temperature have been investigated using the experiment and F.E.M. simulation to develop the precision forging technology for AI7075. When lubricant is applied to both material and die, shear friction factor is 0.1 which shows best effect of lubricant. It is specific corner radius of die that minimized forging load regarding process conditions, especially according to the ratio of the width of rib and web. In conclusion, optimum corner radius is 2~3mm when the width of rib and web is 3mm and 20mm respectively.

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An Automated Process Planning and Die design System for Bolt Products (볼트류 제품에 관한 공정설계 및 금형설계 자동화 시스템)

  • Song, S.W.;Choi, Y.;Jung, S.Y.;Kim, C.;Choi, J.C.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2001.04a
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    • pp.774-777
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    • 2001
  • This paper describes a research work of developing a computer-aided design system of cold forging products. An approach to the system is based on the knowledge-based rules. Knowledge for the system is formulated from plastic theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoCAD with a personal computer and is composed of six modules, which are selection of billet material, input of final product, process planning design, preform modification, insert design, shrink rings design module. Based on knowledge-based rules, the system is designed by considering several factors such as volume constancy, limite of formability by material, preform shape and so on.

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A Development of the Design Supporting System for 2D Multiple Stage Forming (2차원 다단 단조공정의 금형해석 및 금형 설계를 위한 지원시스템 개발)

  • 이영규
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1999.03b
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    • pp.124-128
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    • 1999
  • Since the traditional designing approach of forming processes is based on trial and error it consumes much time and needs cost to design successful processes. Today for higher marketability of products a manufacturing system is required that can reduce production time and enhance product properties greatly. In order to implement the system a computerized design-supporting tool is indispensable for the design and supply of optimized production process for high product quality in short time In this study a design supporting system is developed and implemented to ballstud die. Using the developed system the designer can rapidly produce layouts of dies for each process sequences with consistency.

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A Study on the Cold Forging Development of Guide Valve for the Fuel Pressure Regulator (연료 압력 조절기용 가이드 밸브의 냉간 단조 개발에 관한 연구)

  • Song, Seung-Eun;Kwon, Hyuk-Hong
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.21 no.2
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    • pp.331-336
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    • 2012
  • This study was aimed at the design of the dies for the guide valve for the fuel pressure regulator 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.

Finite Element Analysis on the Cold Forging Process of the Unified Universal Shaft Joint for the Automobile (자동차용 일체형 유니버셜 샤프트 조인트의 냉간단조 공정 유한요소해석)

  • Kwon, Hyuk-Hong;Song, Seung-Eun;Kim, Oh-Seung
    • 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.

Automated Design of Forward Extrusion Die by AutoLISP Language (AutoLISP을 이용한 전방압출 금형의 자동설계 연구)

  • 김종호;류호연;홍기곤
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1997.04a
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    • pp.584-588
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    • 1997
  • Lots of forginfs used in automobile and aerospce industries are made in hot or cold working conditions, depending on the size and shape of a product. Usually the die design for new items has been first made on the basis of experiences and many know-hows accumulated in the company and then slightly modified through trial and error method to get the desired forgings without defects. Most of drawings at the die design stage have been manually drawn, butrecently some of forging companies have begun to apply a computer-aided drafting technique to the die design for reducing drafting time as well as repeatedly utilizing standardized parts form registerd data base. In this paper the automated die design technique for forward extrusion of axisymmetric forgings is developed by using AutoLISP language. For this study the representative die system is determined form the investigation of several types of forging dies being currently employed in the metal forming field and the design rules for cold extrusion die are summarized and programmed on a personal computer. A few design examples of forward extrusion die are given and discusses.

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Multistage Cold Forging Process Design of Al6082 Considering Forming Limit (Al6082의 가공한계를 고려한 냉간단조 공정설계)

  • Ann, Ku-Hee;Kang, Jong-Hun;Heo, Su-Jin;Shin, Tae-soo;Cho, Hae-Yong
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.19 no.9
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    • pp.93-99
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    • 2020
  • Recently, as the weight reduction of vehicles has been actively progressed, parts developed using aluminum 60XX series from existing steel materials are increasing. In this paper, the bushing used for the front frame rail, which is one of the parts for fixing engines and other parts in automobiles, was changed to an aluminum material of the Al60XX series, and it was intended to be produced by applying of cold forging method. The bushing is a part that secures the engine frame, and in order to produce it by cold forging, the molding limit is predicted through process design, and a multi-stage process is designed through finite element analysis. In addition, in order to verify the feasibility of the designed forging process, the limits of the multi-step process were verified based on the Cockcroft Latham theory, and the crack and overlap of the actual forging work were predicted and improved.