• 제목/요약/키워드: Cold Forging Process

검색결과 259건 처리시간 0.03초

정밀냉간단조 기술을 적용한 자동차 액추에이터용 스퍼기어 부품개발 (Development of Spur Gear Parts for Automotive Actuators using Precision Cold Forging Technology)

  • 박동환;한성철
    • 소성∙가공
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    • 제32권6호
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    • pp.335-343
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    • 2023
  • Spur Gear parts for automobile actuators using existing former forging technology were produced in a total of three processes on a former forging machine. However, in order to improve cost increase due to frequent mold breakage, Spur Gear parts were designed and manufactured in the cold forging process after forming the preform through former forging. In other words, in the existing former forging mold, product seating defects occurred due to horizontal movement, resulting in many product defects and mold damage, so there was an urgent need to improve mold life and product defects. In order to improve this, we tried to improve the mold life by improving the existing 3 former forging processes to a former forging process and 2 cold forging processes. Therefore, We developed Spur Gear parts for automobile actuators were developed by applying precision cold forging technology through a former forging process and 2 cold forging processes to improve mold life.

자동차 Steering Yoke의 정밀냉간단조에 대한 연구 (Study on the Precision Cold Forging for Steering Yoke of Automobiles)

  • 민동균
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 1999년도 춘계학술대회논문집
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    • pp.120-123
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    • 1999
  • The precision cold forging process for steering yoke of automobile has been analysed by using rigid-plastic finite element analysis code DEFORM-3D Also the experiment has been performed through the optimized process. Until now steering yoke has been largely manufactured by hot forging or welding of forged head and shaft parts because of technical difficulty. the study has shown successful results of the precision cold forging through the proper selection of the process.

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고압콘덴서용 단자핀의 냉간단조 공정설계에 관한 연구 (A Study on Cold Forging Process Design of a Terminal Pin for High-Voltage Capacitors)

  • 김홍석;윤재웅;손일헌
    • 소성∙가공
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    • 제13권7호
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    • pp.586-593
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    • 2004
  • A terminal pin, which is a part of high-voltage capacitors, has a plate-shaped head section with thickness of 0.8mm. The current manufacturing process, in which the head section is welded on the body part, has given wide deviations of part qualities such as geometrical accuracy, mechanical strength and electrical stability. In this study, a cold forging process sequence was designed in order to produce the terminal pin as one piece. The plate-shaped head section requires an upsetting in the lateral direction of a cylindrical billet, which is followed by a blanking process. The deformed geometry of the lateral upsetting, however, could not be predicted precisely by intuition since metal flows of an axial and a lateral direction of the cylindrical billet would occur simultaneously. Therefore, in this study, three dimensional finite element analyses were applied to the lateral upsetting process in order to determine a proper diameter and height of the cylindrical billet. Once the geometry of the initial billet was determined, intermediate forging processes were designed by applying cold forging guidelines and the designed process sequence was verified by two dimensional finite element analysis. In addition, cold forging tryouts were conducted by using a die set, which was manufactured based on the designed process and finally we found that the part qualities were improved by the proposed cold forging process.

상용차용 중공형 휠 너트 렌치의 냉간단조 공정 개발 (Development of Cold Forging Process of Hollow-type Wheel Nut Wrench for Commercial Vehicles)

  • 김홍석;윤재웅
    • 소성∙가공
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    • 제21권8호
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    • pp.493-498
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    • 2012
  • A wheel nut wrench is one of the hand tools used to loosen and tighten lug nuts on automobile wheels and it has generally a solid-type geometry for commercial vehicles. However, the solid-type wheel nut wrenches manufactured by hot forging processes exhibit several drawbacks such as heavy weight and rough surface finish. Thus, many efforts have been devoted to change the part geometry and improve the manufacturing process. For this purpose, the weight of the final product can be reduced drastically using a hollow tube as the initial stock, which can be manufactured by the more economical manufacturing process of cold forging. In this study, the cold forging of a hollow-type wheel nut wrench for commercial vehicles was designed based on the results of fundamental experiments and CAE analyses using the commercial finite element code DEFORM-3D. In addition, cold forging experiments were conducted on a special-purpose forming machine for hollow wheel nut wrenches in order to validate the designed process sequence. As results, it was found that the final products with a weight reduction of 39% and better surface appearance can be manufactured without any defect with the newly designed cold forging process.

기어블랭크 단조공정의 비교해석 및 공정설계 (A Comparative Analysis and Process Design among the Gear Blank Forging Process)

  • 최호준;허성창;장동환;황병복
    • 소성∙가공
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    • 제8권6호
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    • pp.541-553
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    • 1999
  • Cold forging is a special type of forging process in which metal is forced to flow plastically under compressive force into a variety of shapes in room temperature. Gear blank, which is produced by cold forging, is concerned with the production method of transmission gear. Based on the results of simulation of the current four-stage process, the gear blank forging process for improving the conventional process sequence is designed. The rigid plastic finite element analysis for improving the conventional process. The new process consists of three stage operations with one annealing treatment after first operation. Based on the results of simulation of the proposed process, a required equipment could be selected. The new designed process appears to be more economical in producing the gear blank.

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Axle Shaft 냉간 단조를 위한 최적 수계윤활조건 (Optimal Water Lubrication Condition for an Axle Shaft Cold Forging)

  • 박지원;이종수;최용준;김종호;이석순
    • 한국정밀공학회지
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    • 제27권1호
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    • pp.84-90
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    • 2010
  • The cold forging Process applies surface lubricant coating in order to smooth the friction during the cold forging process. Currently, most of the lubrication processes apply the zinc phosphate coating, which requires 11 steps and disposes sludge. But the water based lubrication process, which has been newly developed, takes 3 steps only and does not cause sludge. In this study, we present the optimal condition of water based lubrication for the cold forging of axle shaft by an experimental design method. Experimental results with minitab shall be able to predict the optimum water based lubricating conditions for the cold forging processes.

전자식 파킹 브레이크용 세레이션 기어의 냉간다단단조 공정 설계 및 후방 압출특성에 관한 평가 (Multi-stage Cold Forging Process Design and Backward Extrusion Characteristics Evaluation of Serration Gear for Electronic Parking Brake)

  • 서주한;최종원;정의은;강명창
    • 한국기계가공학회지
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    • 제21권2호
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    • pp.130-136
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    • 2022
  • Reducing production costs through net-shaped cold forging is an important aspect in the automobile industry. In this study, we intend to produce a net-shaped electronic parking brake (EPB) serration gear for automobiles, using multi-stage cold forging. These serrations are then assembled to the reduction gear of an EPB actuator. The forging process of the serrations and the cold forging design were verified through finite element analysis (FEA) in order to evaluate metal flow. The forging machine was selected by checking the load using FEA. Based on the FEA results, molds were designed, and parts were made using multi-stage cold forging to produce a net-shaped serration gear.

플라스티신을 이용한 BJ형 등속죠인트 외륜의 냉간단조공정설계 (Design of the Cold Forging Process for the Outer Race of BJ Type Constant Velocity Joint using Plasticine)

  • 이정환;이영선;박종진
    • 소성∙가공
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    • 제3권3호
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    • pp.282-290
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    • 1994
  • The outer race of BJ type C.V.Joint has a complicated shape and ball grooves. It is produced by cold or warm precision forging. Especially, the precision level of the ball grooves determines the quality of the part. The objective of the present study is to develop process conditions of the cold forging using the plasticine. Because the cold forging consists of forward extrusion, upsetting, backward extrusion and cold sizing, the study was focused on finding the best perform for each process. The data obtained from the study will be used in the design of the cold forging process for the outer race.

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냉열간 단조기술을 적용한 농기계용 클러치 Jaw 부품 일체화 성형기술 (Integration Forming Technology based on Cold Hot Forging of Clutch Jaw Parts for Farm Machinery)

  • 박동환;한성철
    • 한국생산제조학회지
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    • 제24권5호
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    • pp.489-495
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    • 2015
  • Forging is a manufacturing process involving the shaping of metal using localized compressive forces and the process of deforming metal into a predetermined shape using certain tools and press according to the temperature. Forging provides stronger metal parts than that possible by casting or machining. Conventional clutch jaw parts have been developed through cold forging and precision machining; however, fabrication of integral clutch jaw parts for farm machinery has not been reported yet. These parts were developed by applying a complex forging technology combining cold and hot forging. The integrated forming technology proposed in this study will be useful for reducing the lead-time for manufacturing, improving the accuracy of products, and eliminating the welding process.

회전성형법에서 Rotary Powder Compacting 공정에 관한 특성 연구 (The Rotary Powder Compacting Process by the Cold Rotary Forging)

  • 윤덕재;임성주;최석우;나경환
    • 소성∙가공
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    • 제6권3호
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    • pp.227-232
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    • 1997
  • This study is concerned with the rotary powder compacting by the cold rotary forging process. An experiment has been carried out using the rotary powder forging press(500kN) which was designed and constructed in the authors' laboratory. The detailed comparisons of several mechanical test by rotary powder forging and rotary powder compacting process are given. 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.

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