• Transactions of Materials Processing
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• v.12 no.5
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• pp.498-503
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• 2003

The die for cold forging gets a very high axial load and radial pressure during processing and hence deforms considerably in the radial direction. This radial deformation of die becomes a important factor influencing the dimensional accuracy of a product. In order to obtain the product with highly accurate dimension, therefore, it is essential to acquire some information on elastic deformation of the die and the product. The study has been performed for the relation of the deformation between the die and the product in backward extrusion. The strain of the die has been given by the simple experiment using the strain gauges attached to the outer surface of the die. Also the history of the deformation of the die and the product has been given by the experiment and Lames' formula. The results has been compared with the previous another method. The study has given useful results for the deformation history of the die and the product through the experiment and Lame's formula in backward extrusion, which can be applied in the die design for the product with accurate dimension.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.9
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• pp.32-40
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• 2004

This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. The system is composed of four main modules. The process planning and the die design modules consider several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.433-436
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• 2009

This study is concerned with an effect of frictional condition in a forward/backward combined extrusion process. Generally, the material flow of the billet is influenced by the corners of the die cavity, the ratio in reduction in area, and thickness ratio of backward can thickness to forward can thickness. In addition, the frictional condition in contact area between the billet and the punch/die also affect the material flow. This paper investigated the effect of frictional condition for variable friction factors. The FEM simulation has been carried out in order to examine the effect of frictional condition. Deformation patterns and flow characteristics were examined in terms of design parameters such as extruded length ratio etc. Die pressure exerted on the die-workpiece interface is calculated by the simulation results and analyzed for safe tooling. Therefore the numerical simulation works provide a combined extrusion process of stable cold forging process planning to avoid the severe damage on the tool.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.1
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• pp.29-37
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• 1995

In many metal forming processes, it is common to use stress rings for reducing elastic deformation and failures of forming dies. But, shrink fit of dies inner diameter of die insert, machining is reuqired after shrink fit processes. The reduction of inner diameter can be predicted by the analysis of elastic-plastic finite element method. The dimension of dies before shrink fit can be determined to minimize or remove machining after shrink fit processes by deformation analysis of die. The computation of contacting stresses along die surface was analyzied by rigid plasitic finite element method, and data were interpolated by the contact search algorithm. In this paper, we propose the analysis method of forging dies after shrink fit and forming to improve dimensional accuracy of final products.

• Transactions of Materials Processing
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• v.8 no.2
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• pp.188-199
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• 1999

Semi-Solid Forming Process(Thixoforming, Rheocasting) is a novel forming process which has some advantages compared with conventional die casting, squeeze casting and hot/cold forging. In this study. Thixoforming process was selected as analysis processing in terms of billet handling and easiness of automation process. The Thixoforming process consists of reheating process of billet, billet handling, filling inot the die cavity and solidification of SSM part. In filling process, two rheology models which were Newtonian and Non-Nettonian model (Ostwald-deWaele)were verified with experimental results. The Ostwald-deWaele model shows the good agreement to the real flow and filling phenomena in die cavity. To give a boost the economical efficiency of Thixoforming process and to ensure the good forming result, reheating device coupled die set was proposed and the initial billet temperature for system that was found from experimental resluts. This study presents an overview of application of numerical analysis for simulation of semi-solid metal forming process to reduce the lead time for development of manufacturing part in industrial field.

• Design & Manufacturing
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• v.2 no.2
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• pp.43-47
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• 2008

This paper is concerned with the analysis of material flow characteristics of stepped rod forming. The analysis in this paper concentrated on the evaluation of the design parameters for deformation patterns of tube forming, load characteristics, extruded length, and die pressure. The design factors such as punch nose radius, die corner radius, friction factor, and punch face angle are involved in the simulation. The stepped rod forming is analyzed by using a commercial finite element code. This simulation makes use of stepped rod material and punch geometry on the basis of punch geometry recommended by International Cold Forging Group. As radius ratio is large, forming load was reduced but extruded length ratio was increased.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.2 no.1
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• pp.1-6
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• 2001

This study is concerned with the cold forging of sintered preform by rotary forging process and direct powder compacting process. An experiment has been carried out using the rotary powder forging press (500kN) which had been designed and equipped with the rotational conical die inclined to the central axis of the press at certain angle The effect of process variables was observed and measured by several mechanical test, such as hardness distribution density, and microstructure of the specimens. It is found that the highly densified P/M parts can be obtained and this process is very effective for improving quality of the powder products.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.11
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• pp.977-982
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• 2015

This study uses finite element analysis to evaluate the forming load of tool entrance angle of the cold forward extrusion molding process of helical gear; this can replace the spur gear applied to the Electronic Parking Brake (EPB) system. A cold forging process is often used in the automobile industry as well as in various industrial machines due to its high efficiency. Finite element analysis is frequently used when interpreting results of the forging process. Formality was evaluated by calculating tooth profile filling rate of helical gear. Change in required forming load was investigated when the entrance angle of forward extrusion tool die was changed from $30^{\circ}$ to $60^{\circ}$, also by finite element analysis. We suggest suitable tool entrance angles.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.11
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• pp.223-229
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• 2016

In this study, a cold forging process was developed for the roller tappet housing of an engine valvetrain system. A tappet sample was manufactured and subjected to an endurance test. The material properties were obtained from a compression test, and forging analysis was carried out to design a forging process using a commercial program, Deform-3D. The forging process was set up based on the analysis results, and a die set and sample tappet housing were manufactured. To evaluate the sample, the dimensional accuracy, surface roughness, parallelism, and concentricity were measured and confirmed. To evaluate the actuation and durability, a special test rig was developed to simulate the valvetrain system of the engine. An actuation test was performed based on the idle speed of a general diesel engine, and an endurance test was done based on the maximum speed. The results show minor wear of 0.002 mm. The developed test rig will be used to evaluate the actuation and durability of other valvetrain parts.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.5
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• pp.57-63
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• 2009

Interface friction in blanking dies, cold forging and extrusion of aluminum alloys is a major cause of inefficient process. This paper describes an investigation of femtosecond laser texturing for reduction of interface friction on sliding surfaces in forming process. Femtosecond direct writing technology was used to fabricate a laser micro-machined die and to create microgroove patterns with varying size and density on metal forming dies. A systematic approach to find the optimum parameters and computer simulation comparison of friction coefficients are provided to study the relation of friction coefficients and die profiles. In metal forming tests, the effectiveness of various laser-machined patterns for enhancing interface lubrication is determined.