• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.254-258
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• 2008

Dimensional accuracy is very important quality in micro forged part, especially on forged part. Dimension of forged part is changed continuously during forging process. Loading, unloading and ejecting stage affects dimensional of the forged tool. The elasto-plastic material model for billet and elastic model for die were used to analyze these changes. At same time, the calculated results were compared and analyzed by the experiment on same conditions. From the experimental and analytical studies, we can calculated the amount of difference between die and forged part, that is 0.49% based on the die dimension. The dimensional change is smaller than that of general sized-forged part,0.6%.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.06a
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• pp.23-33
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• 1996

Forging of an inner pulley for compressor clutch assembly of car air conditioner is investigated in this study. In cold forging of inner pulley, the design requirements are to keep the same height of the inner rib and the outer one, and to make uniform the hardness distribution in the forged product. Using the rigid-plastic finite element simulation, we design the optimal process conditions, which has a performing operation. The forged pulley is investigated by checking the hardness distribution and it is noted that the distribution has improved to be even and high enough for industrial application.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.86-89
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• 2000

In cold forging by multi stage former, crowing process is important process for the high production rate and automation of forging process. But various cropping defects occur in cropping process such as orthogonality, ovality and unevenness, etc. These defects have harmful effects on the dimensional tolerance of products and tool life. So in this study, the cropping experiment is performed to examine influence of cropping process variables(clearance, cutting velocity, H/D) on occurrence of crowing defects and optimum process variables are selected, and then FE analysis is performed to verify influence of these defects on dimensional tolerance and tool life.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.381-385
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• 2006

This research introduces easy tool manufacturing method regarding tool manufacturing procedure. In the conventional method, wire cutting machining and lapping operation of corner and render region were performed after shrink-fitting to ensure the accuracy of gear profile. But lapping operation is very difficult due to corner and render is located deep inside of die. In this research, wire cutting operation was performed after $1^{st}$ ring was shrink-fitted to ease lapping operation and increase the accuracy of corner radius. Before $2^{nd}$ ring fitting, lapping was completed. Elastic deformation amount due to $2^{nd}$ ring fitting and cold forging was calculated through finite element analysis and wire cutting specification was offset in that amount. Comparison of gear dimension between analysis and forged part ensures the validity of new manufacturing methods.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.224-230
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• 1998

Non-heat-treated type material has been investigated for formability compared to heat-treated material. It is very important in automation of metal forming, since it has difficulties of controlling heat treating system by the computer and has bottle neck problem related with heat treatment. In this paper, we have concerned about mechanical properties of non-heat-treated material after the forging. To compare the characteristics between heat-treated material and non-heat-treated material, tensile, compression and fatigue test has been performed. Considering results of mechanical properites of non-heat-treated material, it can replace heat-treated material. Therefore non-heat-treated material may be applied to cold forging.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.388-393
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• 2002

Heat-treatment-free steels have been replacing for conventional quenched-and-tempered structural steels since the microalloyed forging steel was developed in early 1970s in Germany. Substantial cost reduction provides the driving force for this change. As a result of intensive R & D efforts and application trials, various kinds of grades, for example heat-treatment-free steels for hot forging, machining and cold heading, have been developed and moreover these steels are in tonnage production throughout the world. The developments in alloy steels, processing conditions and structure-property characteristics of the heat-treatment-free steels, are described and also recent trend and future prospect are summarized in this report.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.217-222
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• 1994

This paper describes the determination of optimal initial billet size for axisymmetric cold forging products using neural networks. The determination of optimal initial billet size is very important in forging design and forming sequence design, because the result of such designs and forming load can be different by variable initial billet sizes. The forming difficulty has been defined as the degree of difficulty in forming by 3 process ' forward extrusion, backward extrusion and upsetting. By neural networks a forming difficulty can be determined with the ratio of shape and forming process. From the graph of maximum, minimum, and average forming difficulties by variable billet sizes, the optimal billet size can be determined. The initial billets of a solid part and a hollow part whichwas determined by this study are compared with the sequence drawing generated by the one of forming sequence design system.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.11
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• pp.21-31
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• 1998

This study described computer aided die design system for cold forging of non-axisymmetric parts. To design the die of cold forging. an integrated approach based on a rule-base system and commercial F. E. code were adopted. This system is implemented on the personal computer and its environment is a commercial CAD package named as AutoCAD. The system includes four modules. In the initial data input module, the variables which are necessary to design of die are inputted by user and die material are selected from the database. In the analysis and redesign module, stress distrubution action on the designed die is analyzed by commercial FEM code NISA II. The designed die is modified to prevent failure in both states of stress free and pressurizing. The developed system provides powerful capabilities for die design of non-axisymmetric parts.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.158-161
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• 2005

In this paper, the precision electric discharge machining technology, the powder electric discharge machining technology, is applied to making a cold forging die for making the helical type of clutch gear. Various working conditions are investigated with emphasis on reduction of the electrode wear and enhancement of the surface roughness. Through the research work, the key technology of making the helical gear forging dies is achieved.

• Fire Science and Engineering
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• v.20 no.4 s.64
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• pp.19-25
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• 2006

In this paper, a new design of the sprinkler branch outlet for fire-extinguishing purposes is presented together with its manufacturing process. The conventional three-piece design is improved by a new one-piece design with the help of the manufacturing technology of cold forging. The forging process is simulated and optimized by the rigid-plastic finite element method and the design tryouts are thus minimized. It has been shown through its applications that the presented system is much more economical and structurally stronger.