• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.114-120
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• 2008

This study is to compare and analyze the material flow, deformation characteristics, and forming load of flange by means of similitude experimental method of model material using plasticine. In order to find optimal forming conditions, prototype experiments were designed to investigate forming characteristics of general-purpose flange under various working conditions. As a result of prototype experiments, billet thickness and gap-height ratio was found to be the most influential experimental parameter in flange forming. Forming loads from prototype experiments were compared to the results of finite element analysis after conducting estimation of forming loads of real material. Results of prototype experiments based on model material techniques are expected to be used as a basic data of die design f3r the development of products and process.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.12
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• pp.168-175
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• 2003

In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effects of process variables such as gap height, relative gap width and die corner radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.

• Transactions of Materials Processing
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• v.9 no.3
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• pp.242-248
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• 2000

This paper is concerned with the family of parts that generally feature a central hub with radial protrusions. Radial Extrusion is usually used in order to produce complex parts, which is combined with upsetting and/or forward and backward extrusion. Typical parts that fall into this category include cross pieces for universal joints, key-shaft type parts, tube fittings, and differential gears. In this paper, the forming characteristics of radial extrusion combined with forward extrusion is investigated by comparing the punch and mandrel loads. The design factors during radial extrusion combined with forward extrusion are applied to the simulation to see how much those factors have effect on the forming loads. The rigid-plastic FEM is applied to the simulation.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.10
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• pp.76-83
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• 2001

This paper is concerned with the analysis of the forming characteristics of radial-backward extrusion. The single action pressing is analyzed by using the rigid-plastic FEM. The design factors such as die corner radius, gap height, and friction factor are involved in the simulation. The analysis is focused on the influences of the design factors on the maximum punch farce and metal flow into can and flange region. As a result of analysis, the gap height among the design factors is known to have a major effect on the metal flow of radial-backward extrusion for single action pressing compared with other design factors. As is expected, forming load and volume of flange increase as gap height and die corner radius increase, respectively.

• Design & Manufacturing
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• v.2 no.1
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• pp.7-10
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• 2008

Restriking method is to add to process in order to get the correct size and high precision accuracy of product which is formed in pre-process. This method is widely used at bending work and drawing work. Restriking die is particularly design and used as restriking process is performed. Therefore, production cost is increasing as one process or a two process are added. In this paper, punches and die block of square shell drawing die which could be performed drawing work and restriking process by using only one die are designed in order to solve these factors. The structure of sectional die which can integrate drawing die and restriking die was developed.

• Transactions of Materials Processing
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• v.8 no.6
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• pp.604-611
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• 1999

This paper is concerned with the family of parts that generally feature a central hub with radial protrusions. As opposed to conventional forward and backward extrusion, in which the material flows in a direction parallel to that of the punch or die motion, the material flows perpendicular to the punch motion in radial extrusion. Three variants of radial extrusion of a collar or flange are investigated. Case I involves forcing a cylindrical billet against a flat die, Case II involves deformation against a stationary punch recessed in the lower die, and Case III involves both the upper and lower punches moving together toward the center of the billet. Extensive simulational work is performed with each case to see the process conditions in terms of forging load, balanced and symmetrical flow in the flange. Also, the effect of the gap size and die corner radii to the material flow are investigated. In this study, the forming characteristics of radial extrusion will be considered by comparing the forces, shapes etc. The design factors during radial extrusion are investigated by the rigid-plastic FEM simulation.

• Transactions of Materials Processing
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• v.12 no.3
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• pp.228-235
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• 2003

In this paper, the workability of flange in the radial extrusion is analyzed in terms of the deformation pattern, the punch load and the forming limit by using simulation and experiment. A single action pressing is applied to both simulation and experiment. The analysis in this study is focused on the transient extrusion into the gap in radial direction with various gap heights and die corner radius. Based on the surface strains where surface cracking occurs, the forming patterns and strain-fracture relationships in producing radially extruded flange are obtained.

• Transactions of Materials Processing
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• v.12 no.3
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• pp.251-258
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• 2003

The paper deals with an analysis of an extrusion process with a divided material flow in a combined radial - backward extrusion. The paper discusses the influences of tool geometry such as punch nose angle, relative gap height, die comer radius on material flow and surface expansion into can and flange region. To analyze the process, numerical simulations by the FEM and experiment, an Al alloy as a model material have been performed. Based on the results, the influence of design parameters on the distribution of divided material flow and surface expansion are obtained.

• Transactions of Materials Processing
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• v.11 no.1
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• pp.84-89
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• 2002

This study is concerned with the analysis of the forming characteristics of radial-forward extrusion. Angle between radial and forward extrusion, gap height, and friction factor are considered as important design factors to affect forming characteristics in radial-forward extrusion. The rigid-plastic finite element method is adopted to analyze the effects of design factors on forming loads. The incremental rates of loads are nearly constant except the deformation zone from radial to forward extrusion. The smaller angle induces lesser force increment, therefore forming load increases as the angle increases. Maximum load also increases as gap-height decreases and friction factor increases.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.05a
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• pp.75-78
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• 1999

This paper is concerned with the family of parts that generally feature a central hub with radial protrusions. Typical parts that fall into this category include cross Pieces for universal joints, tube fittings, and differential gears. As opposed to conventional forward and backward extrusion, in which the material flows in a direction parallel to that of the punch or die motion, the material flows perpendicular to the punch motion in radial extrusion. In this study, the forming characteristics of radial extrusion will be considered by comparing the forces, shapes etc. The design factors during radial extrusion are investigated by the rigid-plastic FEM simulation.