• Journal of the Korean Society for Precision Engineering
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• v.17 no.3
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• pp.149-157
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• 2000

Tool wear in the shearing process such as blanking, piercing and trimming is very important, because it has great effects on the dimensional accuracy, working efficiency and economy. Most of tools in the shearing process have the coated layer at surface fur good wear and corrosion resistance. When the surface of tool is teated, the wear Phenomena of coated surface layer and inner layer may be different. This paper describes a computer modelling technique by the finite element method in order to investigate the wear mechanism and to predict the wear profile of Ti-N coated tool in piercing process according to the volume of Production. Wear coefficients of the coated layer and inner layer are obtained through Pin-on-Disk wear test, respectively. To verify the effectiveness of the suggested technique, the technique is applied to wear analysis in piercing recess of piston pin and simulation results are compared with experimental ones.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.204-208
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• 1995

Copper magnetron anode of a microwave-oven consists of an cylindrical outer-tube and various inner-vanes. The magnetron anode is produced by the complex process ; vane blanking, pipe cutting and sliver-alloy brazing of vanes. Recently, the backward extrusion process for forming vanes has been developed to avoid the complex procedures. The developed process is analyzed by using upper-bound elemental technique(UBET). In the UBET analysis, the upper-bound load, the configuration and the vane-height of final extruded product are determined by minimizing the total power consumption with respect to chosen parameters. To verify theoretical analysis, experiments have been carried out with pure plasticine billets at room temperature, using different web-thickness and number of vanes. The theoretical predictions both for forming load and vane-height are in reasonable agreement with the experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.231-234
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• 2001

Shearing, including blanking, trimming, piercing, etc, is one of the most frequently used processes in sheet metal manufacturing. In this paper, an individual set of tooling with an in-die sensor was designed and precisely fabricated to carry out the experiment for the shearing process investigation. Through various experiments, it has been examined the influence of process parameters such as clearance, edge material properties and pad configuration. Since the tension between the part and the scrap increases when the clearance increases, the clearance should be selected properly in order to reduce the burr height. Also removal of the lower pad makes the sheared surface worse and the shearing system unstable. The shearing force increases when the clearance decreases and the friction of the tooling material decreases. Dynamic reaction force is also important to obtain the fine sheared surfaces.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.1
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• pp.167-174
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• 2012

For high production rate of parts requiring multiple operations such as punching, blanking, or other operations are generally done with progressive dies. However, progressive die is generally limited to use for sheet metal forming due to the technical difficulties in rod or bulk material. This study proposes a new technique of progressive die and forming process for asymmetric automotive door striker, which is conventionally manufactured with separate tandem processes using solid rod. In order to design forming process and die, FEM simulation was performed to divide proper intermediate processes and analyze its formability. As a result, Forming processes were divided into 3 stages with upper and side punches and also, workpiece feeding and location mechanism was designed and manufactured in this study. Finally, forming tryouts were carried out by using the manufactured progressive die to verify the forming quality and productivity.

• Transactions of Materials Processing
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• v.23 no.8
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• pp.501-506
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• 2014

Progressive shearing with blanking dies is commonly employed to produce large quantities of tiny sheet metal electronic parts. Sheet metal pins, which are narrow and long, that are sheared with a progressive die set are often twisted. The twist in the sheet metal pins, which usually occurs in the final shearing operation, generally decreases with increasing blank holding force. The blank holding forces in all shearing operations are not the same because of different shearing positions and areas. In the current study, the optimal layout of the springs in a progressive die set to minimize the twist of the sheet metal pin is proposed. In order to find the holding force acting on the tiny narrow blanks produced with the proposed springs during the shearing process, the equivalent area method is used in the structural analysis. The shearing of the sheet-metal pin was simulated to compute the twist angle associated with the blank holding force. The constraint condition satisfying the pre-set blank holding force from the previous shearing operations was imposed. A design of experiments (DOE) was numerically implemented by analyzing the progressive die structure and by simulating the shearing process. From the meta-model created from the experimental results and by using a quadratic response surface method (PQRSM), the optimal layout of the springs was determined. The twist of sheet metal pin associated with the optimal layout of the springs found in the current study was compared with that of an existing progressive die to obtain a minimal amount of twist.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.9
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• pp.126-136
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• 1995

Copper magnetron anode of a microsave-over consists of an cylindrical outer-tube and various inner-vanes. The magnetron anode is produced by the complex processes; vane blanking, pipe cutting and silver-alloy brazing of vanes. Recently, the backward extrusion process for forming vanes has been developed to avoid the complex procedures. The developed process is analyzed by using upper-bound elemental technique (UBET). In the UBET analysis, the upper-bound load, the configuration and the vane-height of final extruded product are determined by minimizing the roral power consumption with repect to chosen parameters. To verify theoretical analysis, experiments have been carried out with pure plasticine billets at room temperature, using different web-thickness and number of vanes. The theoretical predictions both for forming load and vane-height are in reasonable agreement with the experimental results.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.4
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• pp.6-11
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• 2002

Formability in deep drawing process depends not only on a drawability of workpiece material but also on process conditions such as die punch comer radius, lubricant conditions, punch-die clearance etc. For instance, bending resistance should be reduced by increasing die round appropriately, drawing load should be minimized by improving the lubricant condition between die and material, and blanking load should be increased by selecting a pertinent punch round and by augmenting the friction resistance in punch. In this study, a multi-stage deep drawing process is analyzed using ABAQUS. The effects of formability factors, such as die shoulder radius, punch-die clearance and friction coefficient are investigated, and the results are also discussed in detail.

• Journal of Power System Engineering
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• v.15 no.4
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• pp.60-64
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• 2011

Computer-aided engineering (CAE) is the broad usage of computer software to aid in engineering tasks. It includes computer-aided design (CAD), computer-aided analysis (CAA), computer-integrated manufacturing (CIM), computer-aided manufacturing (CAM), material requirements planning (MRP), and computer-aided planning (CAP). In this study, the stress of mold analyzed using CAE technique. Punch loads were same difference between 0.5 % and 1.0 % of clearance, but punch load was decreased according to increasing of clearance. Punch load of pre-piercing process worked a little smaller than piercing process. Therefore, the hole of fine blanking process is also more efficient to manufacture the true size after pre-piercing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.179-188
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• 2003

The objective of our study is to investigate the micro fabric ability by conventional metal forming processes. In the present investigation, micro hole punching was studied. We tried to control punching process at the micro level and scaled down the standard blanking condition for $25{\mu}m$ hole fabrication. To accommodate this, tungsten carbide tooling sets and micro punching press were carefully designed and assembled meeting accuracy requirements for $25{\mu}m$ hole punching. With our developments, 100, 50, and $25{\mu}m$ holes were successfully made on metal foils such as brass and stainless steel of 100, 50, and $25{\mu}m$ in thickness, respectively, and hole sizes and shapes were measured and analyzed to investigate fabrication accuracy. Shear behavior during micro punching was also discussed. Our study showed that the conventional punching process could produce high quality holes down to $25{\mu}m$.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.448-452
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• 2005

Punching/blanking/shearing is among the oldest and most frequently used sheet metal forming process. We have developed the shear device for burrless cutting using the micro wire. Since the burr minimization and fine shear plane, this paper is a study on the effect of the shear angle and clearance of the cutter-cutter. And, we confirm the tendency of the shear plane. It is impossible to completely remove the burr in the shearing process. In order to minimize the burr size and fine shear plane, we have accomplished the various experiment conditions such as the shear angle and clearance. Despite the quality of shear plane is not good enough yet, it is possible to make the burr minimization and fine shear plane by the optimization of process parameters.