• Transactions of Materials Processing
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• v.32 no.6
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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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.139-142
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• 2009

As important mechanical elements, gears have been used widely in power transferring systems such as automobile transmission and there have been several researches trying to make gear parts with cold or warm forging in order to reduce cost and time required to gear manufacturing process. Although forging processes of spur and bevel gears have been developed as practical level owing to active previous researches in Korea, the manufacturing of helical gear has been still depended on traditional gear cutting processes such as hobbing, deburring and shaving. In order to manufacture helical gears with cold forging process, a research project supported by government has been conducted by Daegu university, KIMS and TAK and this paper deals with effects of back pressure forming technique to cold forging of helical gear as a fundamental research.

• Transactions of Materials Processing
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• v.8 no.6
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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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.135-138
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• 2004

Since the upsetting type is superior to an extrusion type to get the dimensional accuracy of cold forged spur gear, the upsetting type process far spur gear cold forging has been studied. FE analysis of upsetting type process fur spur gear cold forging was performed to investigate about flow pattern of workpiece and die stress. To analyze the elastic characteristics of die, both rigid and elastic material model were used during loading stage. Under-filled defects were detected In lower portions of spur gear forged by upsetting type in experimental. When the elastic material model for die was used, the under-filled defects could be predicted. On the other hand, if the material model of die was rigid, the defects could not been presented because the die deflection was not considered.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.8
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• pp.2458-2467
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• 1996

The rigid-plastic finite element analysis was performed for analysis of ofhot forging and cold sizing of a bevel gear. Two dimensional analysis was carried out to investigate the defect occurrence on vertical symmetric planes during hot forging and three dimensional analysis was to understand the filling behavior on horizontal planes during cold sizing. The involute curve of a tooth was approximated by a circle for convenience in the present analysis. In order to estimate the elastic deformation of the gear and dies during cold sizing, linear elastic finite element analysis was performed. Results of the analysis can be used to predict grain flows and strength distributions in the forged gear, and to design dies and an appropriate preform for the cold sizing.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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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.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.384-392
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• 1999

In metal forming, there are problems with recurrent geometric characteristics without explicitly prescibed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. In this paper, as a practical application of the proposed method, the precision cold forging of a helical gear has been simulated by a three-dimensional rigid-plastic finite element method and compared with the experiment. The application of recurrent boundary conditions to helical gear forging analysis is proved to be effective and valid. the elastic stress analysis of the die for helical gear forging has been calculated by using the nodal force at the final stage obtained from the rigid-plastic finite element analysis. In order to obtain more precise gear products, the elastic analysis of the die after release of punch and the elastic spring-back analysis of product after ejection have been performed, and the final dimension of the computational product has been in good agreement with that of the experimental product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.44-48
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• 2003

In metal working, cold forging that has profit to satisfy dimension accuracy is using in various manufacturing products. Recently, most of the interest thing is precision forging of gear, Gear forging product is more strength than broaching gear, and it has many advantages with reduction of factory expenses. The reason of difficulty to improve accuracy of gear dimension compare to another products is the dimension accuracy is very high, approximately 10$\mu\textrm{m}$, and because die of involute teeth and elastic strain of forged tool differ from standard curve. This paper represent quantitative analysis of die and teeth of forged tool, namely difference of curves, with experiments and analyze the factor of dimension gap, finally, will design compensated involute curve.

• Transactions of Materials Processing
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• v.6 no.6
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• pp.500-507
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• 1997

The conventional closed-die forgings had been applied to the forging of spur gears. But the forgings require high forging-pressure. In this paper, new precision forging technology have been developed. The developed technology is two steps forging process. Good shaped products are forged successfully with lower forging-pressure than those of conventional forging. The accuracy of the forged spur gear obtained by new precision forging technology is set nearly equal to that of cut spur gear of fourth and fifth class in Korean industrial standard.

• Transactions of Materials Processing
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• v.5 no.2
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• pp.105-114
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• 1996

Recently, precision forging techniques are applied to manufacture spur gears. Compared to conventional machining, they produce parts of better mechanical properties and less residual stresses with a much higher production rate. In the present investigation a rigid-plastic three dimensional finite element method was applied to analyze hot forging and cold sizing of a spur gear by closed dies. The involute curve of a tooth profile was approximated by a circle close to the curve. Results of the analyses make it possible to predict local strengths of the gear die failure and an appropriate preform for cold sizing. It was found that the preform for cold sizing. It was found that the preform for the cold sizing is the most important because it determines whether the gears especially teeth can be successfully formed.