• Transactions of Materials Processing
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• v.4 no.1
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• pp.28-38
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• 1995

An integrated process planning system can determine desirable operation sequences even if they have little experience in the design of multistage cold forging process. This system is composed of seven major modules such as input module, pre-design module, formability check module, forming sequence design module, forming analysis module, FEM verification module, and output module which are used independently or in all. The forming sequence for the part can be determined by means of primitive geometries such as cylinder, cone, convex, and concave. By utilizing this geometrical characteristics(diameter, height, and radius), the part geometry is expressed by a list of the primitive geometries. Accordingly, the forming sequence design is formulated as the search problem which starts with a billet geometry and finishes with a given product one. Using the developed system, the sequence drawing with all dimensions, which includes the dimensional tolerances and the proper sequence of operations for parts, is generated under the environment of AutoCAD. Several forming sequences generated by the planning system can be checked by the forming analysis module. The acceptable forming sequences can be verified further, using FE simulation.

• Transactions of Materials Processing
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• v.14 no.5 s.77
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• pp.423-431
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• 2005

In this paper, a systematic attempt for estimating geometric dimensions of cold forgings is made by finite element method and a practical approach is presented. In the approach, the forging process is simulated by a rigid-plastic finite element method under the assumption that the die is rigid. With the information obtained from the forging simulation, die structural analysis and springback analysis of the material are carried out. In the springback analysis, both mechanical load and thermal load are considered. The mechanical load is applied by unloading the forming load elastically and the thermal load is by cooling the increased temperature due to the plastic work to the room temperature. All the results are added to predict the final dimensions of the cold forged product. The predicted dimensions are compared with the experiments. The comparison has revealed that predicted results are acceptable in the application sense.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.6
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• pp.57-62
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• 2015

A large variety of pipe flanges are required in the marine and construction industry. Pipe flanges are usually welded or screwed to the pipe end and are connected with bolts. This approach is very simple and has been widely used for a long time; however, it results in high development costs and low productivity, and the products made through this approach usually have safety problems in the welding area. In this research, a new approach for forming pipe flanges based on cold forging and the floating die concept is presented. This innovative approach increases the effectiveness of the material usage and saves time and costs compared with the conventional welding method. To ensure the dimensional accuracy of the final product, finite element analysis (FEA) was carried out to simulate the process of cold forging, and orthogonal experiment methods were used to investigate the influence of four manufacturing factors (stroke of distance, pin die angle, forming of pipe diameter, and speed of the die) and predict the best combination of them. The manufacturing factors were obtained through numerical and experimental studies, which show that the approach is very useful and effective for the forming of pipe flanges and could be widely used in the future.

• Transactions of Materials Processing
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• v.14 no.8 s.80
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• pp.675-680
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• 2005

This study was aimed at the design of the dies for the automobile part for the engine oil leakage prevention using the computer simulation to shorten the period of production, on the basis of the process planning which was designed by the field experts. In the computer simulation,'eesy-2-form' of 2D FEM simulation package and 'eesy-DieOpt' have been used, which are the commercial process analysis and die design program. Through the simulation of 'eesy-2-form', we could know the propriety of the forming process, the inner pressure of the die and the suitable fitting pressure between the insert and the sleeve which was not showing any positive tangential stresses in the insert. Through the simulation of 'eesy-DieOpt', we could know the number of the stress ring, the diameter ratios, the stresses of the die, the shrink fitting tolerance and temperature in the condition of the already determined maximum outer die diameter of the multi-stage former. The validity of the die design using the computer simulation was analyzed by the experiments and the results were satisfactory. As the results of this study, the new and easy die design system for cold forging has been developed.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.7
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• pp.827-833
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• 2011

Precision forging of gears has a lot of advantages when compared to conventional gear shaping, because it allows the manufacture of gear parts without flash and consequently without the need for subsequent machining operations. In this study, the cold forging process is determined to manufacture the cold forged product for the precision clutch gear used of a commercial automobile, To do this, shape ratio of initial shape having influence the forgeability of forged product is analyzed. The optimal initial shape of clutch gear is designed using the results of DEFORM-3D and the artificial neural network (ANN). The initial shape through the detail analysis results, such as metal flow, distributions of strain can be obtained.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.87-90
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• 2004

In this paper, net-shape forming of an automobile gear is investigated. Barrel, a component of automobile start motor, is adopted as a net-shape forming. In order to accomplish the goal of net-shape forming without cutting of tooth and cam after forming, forming ability is raised through billet treatment and die design. As a technique of billet treatment spheroidizing annealing of billet to get low hardness and molybdenum disulphide coating to get low contact friction between billet and die is carried out. One of critical points of die design, fillet radii variation of tooth of die is applied to get smooth surface of barrel after cold forging. As a measurement of tooth accuracy, distance between two pins and lead-tooth alignments are investigated. Cam profile accuracy is checked with a 3D measuring instrument. Results obtained from the tests revealed reasonable result with respect to design goal. By these results, the paper shows that reasonable results can be obtained by billet treatment and die design for net-shape forming.

• Transactions of Materials Processing
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• v.20 no.7
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• pp.485-490
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• 2011

The application of helical gears in crucial parts of automotive transmissions has been steadily increasing due to their higher power transfer performance compared to spur gears. However, the traditional gear manufacturing methods such as hobbing and deburring require large cycle times with expensive production lines so that there have been intensive efforts trying to manufacture gears via forging processes. Although forging processes for spur and bevel type gears have been developed on the practical level, the manufacturing of helical gears is still dependent on the traditional cutting process. Therefore, this paper seeks to develop a cold forward extrusion process for the helical gear with the pitch diameter of 43.5mm and a helix angle of $18.4^{\circ}$. A forward extrusion process was used due to the relatively small diameter of the target geometry. The material deforming behavior influenced by the die geometry was examined by using CAE analysis. Finally, it was found that the helical gear manufactured by the developed extrusion process satisfied the dimensional accuracy and mechanical characteristics for automotive transmissions.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.405-413
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• 2002

A process planning system for cold forging of non-axisymmetric parts of comparatively simple shape was developed in this study. Programs for the system have been written with Visual LISP in AutoCAD. Shape of the product must be drawn with the solid line and the hidden line, and with the plane and front view, as well. At the plane, the system recognizes the external shape of non-axisymmetric portions - the number of the sides of the regular polygons and the radii of circles inscribing and circumscribing the polygon. At the front view, the system cognizes the diameter of axisymmetric portions and the height of the primitive geometries such as polygon, cylinder, cone, concave, convex, etc. The system perceives that the list developed from the solid line must be formed by the operation of forward extrusion or upsetting, and that the list developed from the hidden line must be formed by the operation of backward extrusion. The system designs the intermediate geometries again by considering clearance between workpiece and die, and then finally the billet diameter, in reverse order from the finished product, on the basis of volume constancy and using the operations, the forming sequence, the number of operations and the intermediate geometries which were already designed. The design rules and knowledges for the system were extracted from the plasticity theories, handbook, relevant reference and empirical knowledge of field experts. Suitability of the process planning was analyzed using SuperForge of FVM simulation package. The results of analysis showed good formability.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.125-126
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• 2006

The characteristics of the tool system give many effects into the costs and qualities for the finished components. Therefore, a tool life is one of the important issues on cold forging industry. However, since variables related with tool life are many complicated, the studies for solution should be investigated by the systematic research approach. In this study, heat-treatment of tool material is investigated to improve the tool life. Deep cryogenic treatment of tool steel is very efficient to improve the wear resistance due to the fine carbide. And, it is investigated that the shape and dimension of tool give effect into both tool life and quality of forged product.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.2
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• pp.653-659
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• 2014

Computer simulation has been performed to optimize cold forging process of automotive LPI fuel filter housing. A mold and the test product have been manufactured considering the strain and load distribution during the cold forging process. Also, fuel flow simulation has been performed to analyze flow characteristics of existing model and new model. Simulation result shows that two models have equivalent pressure drop. Compared with the mass of existing product, raw material reduction of 16 g and 30.5 g has been achieved from the upper and lower housing, respectively. Total mass reduction of the new housing was 46.5 g. Leak test and internal pressure test have been performed to verify the safety standard and test results were satisfactory.