• 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.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.575-578
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• 2000

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation for the die wear is too hard because the prediction of the die wear is determined with many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard's wear model in order to reduce the rapid wear rate that is generated for the backward extrusion product exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat, angle, and round of the punch nose part. As the flat and angle of the punch nose are larger, the surface expansion is reduced. and, the wear rate is decreased according to the reduction of the punch round. These results obtained through this study are applied to the real manufacturing process, it is implemented the reduction of the wear rate.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.10
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• pp.180-187
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• 2004

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation fur the die wear is too hard because the die wear is caused by many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard wear model in order to reduce the rapid wear rate that is generated for the backward extruded products exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat diameter, angle, and round of the punch nose part. As the flat diameter and angle of the punch nose are larger, the surface expansion is reduced and the wear rate is decreased according to the reduction of the punch round. These results obtained through this study can be applied to the real manufacturing process.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.8 s.197
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• pp.34-40
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• 2007

In this study, focusing on reducing a load in forming helical gears, the extrusion using two-step processes for manufacturing helical gear is proposed. The process is composed of the extrusion step in which spur gear to be used as a preform in next step is formed, and the torsion step in which the preform of spur gear is formed to helical gear. Upper-bound theory for the two-step process is applied and compared with the results of experiment. The result of upper-bound solution has a good agreement with that of the experiment and the FE analysis. The newly proposed method can be used as an advanced forming technique to remarkably reduce a forming load, to prolong a tool life, and to replace the conventional forming process of helical gears. Results obtained from the extrusion using two-step processes enable the designer and manufacturer of helical gear to be more efficient in this field.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.11
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• pp.106-113
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• 1996

Using stainless steel as the cold forged parts especially the outer parts of automobile is gradually increasing because it can bear up against the erosion and the wear. During cold forging of the stainless steel the working pressure acting on die surface are very high therefore the wear on die surface can be greatly increased. In cold forging processes, die failure must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The die wear affects the tolerances of forged parts, metal flow and costs of processes etc. The only way to to control these failures is to develop methods which allow prediction of the die wear and which are suited to be used in the desing stage in order to optimize the process. In this paper, the rigid-plastic finite element method was combined with the wear prediction routine and then the forward extrusion process using stainless steel was analysed simultaneously. To minimize the die wear the FPS algorithm was applied and the optimal conditions of die configuration are suggested.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.9
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• pp.118-124
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• 2002

The use of ceramic inserts in hot extrusion dies offers significant technical and economic advantages over other forms of manufacture. In this paper, 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 deflections generated in shrink fitting the die inserts and that caused by the stresses generated in the process. The shrink fit analysis has been performed that enables optimal design of the dies taking into account the elastic deflections which generated in shrink fitting the die inserts and that caused by the stresses generated in the process and by using DEFORM software for process analysis. 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 die design. 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. The results are compared with the experimental ones for verification.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.5 s.182
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• pp.51-58
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• 2006

The necessities for heightening fuel efficiency as well as lightweight design, lead to an increase of the use of aluminum alloys in the automobile industry. Extruded aluminum profile channels are used widely for the design of frame parts as lightweight assemblies, especially if a high stiffness is needed. While many applications can be realized with forming of hollow square-sectioned extruded profiles such as a stretch bending and a hydro-forming, some applications demand the use of a press bending which can be hardly found in the previous study. In this study, by introducing the use of a press bending into car sub-frames, the demands for higher accuracy as well as higher flexible method than the conventional methods will be satisfied. With respect to the design of sub-frames, the process planning was performed from the shape of a sub-frame product. The designed processes were analyzed by the commercial FEM code, DEFORM-3D. Forming dies for the each process were designed and prototypes of sub-frames were manufactured by the verified farming process. In addition, some of the important features of design parameters in the press bending were reviewed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.824-828
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• 2002

Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.1
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• pp.120-127
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• 2013

A novel severe plastic deformation process named half channel angular extrusion (HCAE) is proposed in order to produce bulk UFG materials. In HCAE process, equal channel angular extrusion (ECAE) and conventional forward extrusion process is integrated to increase the strain per pass and effectiveness of the SPD process. Three-dimensional finite element analysis was carried out to study the deformation behavior of the materials in the HCAE process. HCAE process was performed experimentally on commercially pure aluminum (AA1050) and micro-Vickers hardness test was used to measure the distribution of hardness on the section of normal to the extrusion direction. The results show that HCAE is able to impose more intensive strains per pass and give rise to higher micro-hardness than ECAE.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.7
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• pp.53-61
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• 2004

Condenser tube which is used for a cooling system of automobiles is mainly manufactured by conform extrusion. However, direct extrusion using porthole die in comparison with conform extrusion has many advantages such as improvement of productivity, reduction of production cost etc. In general, the porthole die extrusion process is useful for manufacturing long tubes with hollow sections and consists of three stages(dividing, welding and forming stages). Especially, Porthole die for producing condenser tube is very complex. Thus, in order to obtain the detailed mechanics, to assist in the design of proper die shapes and sizes, and to improve the quality of products, porthole die extrusion should be analyzed in as non-steady state as possible. This paper describes FE analysis of non-steady state porthole die extrusion for producing condenser tube with multi-hole through 3D simulation in the non-steady state during the entire process to evaluate detailed metal flow, temperature distribution, welding pressure and extrusion load. Also to validate FE simulation of porthole die extrusion, a comparison of simulation and experiment results was presented in this paper.