• 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.16 no.6
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• pp.3692-3697
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• 2015

A screw is a type of fastener characterized by a helical ridge known as thread. The demands for screws with the miniaturization and weight reduction are increasing for the trend of small size of mobile devices. The successful designs of mold and process are very important to obtain screws with good mechanical properties and high precision. In this study, the design of cold forging process of micro screw was carried out by using finite element method. In particular, in order to investigate the effects of die geometries and friction, design of experiment method was adopted and it was revealed that the friction was the dominant factor of folding defects. From these results, the design of die was modified and experiments were carried out with the modified die. From the experimental results, it was found that the folding defects disappeared.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.4
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• pp.423-430
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• 2010

Hot closed-forging process and the die used for forming an automotive flange were analyzed from the viewpoints of heat transfer, grain-flow lines, and stresses to obtain a forged product without defects such as surface cracks, laps, cold shots, and partial filling. The forging process including up-set, pre-forging, final forging and pressing forces was investigated using finite element analysis. The influence of the preform die and the ratio of the heights of the upper die to lower die on the forging process and die were investigated and a die shape ($10^{\circ}$ for the preform die, and 1.5:1 ratio for the final die) suitable to achieve successful forging was determined on the basis of a parametric study. All parametric design requirements such as strength, full filling, and a load limit of 13,000 KN were satisfied for this newly developed flange die. New dies and flanges were fabricated and investigated. Defects such as partial filling and surface cracks were not observed.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.6
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• pp.395-399
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• 2017

The LPI fuel filter housings used in automobiles were made from conventional die castings but have recently been developed by cold forging to improve the weight and durability. On the other hand, a sink may develop at the core of the forged product due to the resulting T-shape, which not only reduces the aesthetics, but also increases the post-processing cost of the product. Therefore, this research focused on methods to predict and mitigate sink development and progression during the T-shape forging process. Finite element analysis of the forging process was first performed to determine the optimal initial workpiece devoid of burrs and underfills. An accurate sink prediction was then obtained via metal flow analysis, which was a result of the finite element simulation. Through finite element analysis, it was confirmed that sink development is a product of the differences in nodal velocities arising from the T-shaped forging process. Consequently, a pad was inserted beneath the sink to minimize these velocity differences. The results yielded significant improvement with regard to the sink defect. This method was practically applied to an industrial site to validate the sink improvement.

• Transactions of Materials Processing
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• v.14 no.5 s.77
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• pp.439-443
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• 2005

Deep drawing and cold forging processes are combined to achieve near net shape forming of automotive part which has not only drum shape but also thickness variation. It is important to find out proper intermediate shape where two totally different forming methods should be joined seamlessly. In the course of development of the combined process, finite element analysis can be utilized effectively to decide optimal position for transferring from the sheet metal work to the bulk forming. Because machining process is eliminated, significant improvement in integrity, reliability, and durability of the part is expected. The developed process combination could be applied in real manufacturing process successfully.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1997.04a
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• pp.54-61
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• 1997

Furthermore the rothor pole, with a solid type, manufactured by cold forging process at present should dmploy 3 press lines which consist of total 7 processes. Since A.S.B. treatment is prerequisite for the press line, the 3 times of A.S.B. treatment requires a long lead time, with little contribution to the reduction in cost. The author has investigated, through this researach, the possibility of a new forging method for a rotor pole production with (1) 2 pass instead of 3 press lines (2) only one A.S.B. treatment instead of 3 ones (3) solid type instead of sectional type, and (4) improvment of material property during process using a modified forging process and a specially designed die.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1097-1100
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• 2004

A rear axle spider in an irregular shape, which is used as a part in the braking system of a vehicle like a big truck and a trailer, is subjected to a large torque and hence requires both strength and endurance over the brake heat. This part should be therefore manufactured in dimensional accuracy. The practical manufacturing process of this irregular product requires the heat treatment process after hot forging and then the cold coining process for the dimensional accuracy. At the present study, the warm coning without the heat treatment process was proposed to employ the residual heat due to the hot forging process. And also the trimming and piercing process was designed using the rigid-plastic finite element method. The mechanical properties were discussed and also commented upon.

• Transactions of the Korean Society of Automotive Engineers
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• v.12 no.3
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• pp.122-129
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• 2004

In plastic working, as working becomes speedy, automatic and working condition deteriorates, the increase of forging working has been remarkable. Therefore, we need the estimation of mold lift in detail, in order to counterplan of effective mold life extension. In this study, on the SKH51, mold steel which is forged by cold working and the KCW1, tool steel of low alloy, we estimated mold life on the base of FEM analysis and investigated mold lift by low cycle fatigue test. Also, this paper suggested a new method of estimation of mold lift.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.82-85
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• 2000

In cold forging, the final product is usually given by multi-stage process and the preform with stepped shape can be manufactured through the various forging method. The forward extrusion and upsetting processes for preform with stepped shape have been analyzed by using the rigid-plastic finite element analysis code, InteFORM and compared for load and stroke according to ae reduction of weを An engineer should select the proper processes considering the capacity and the stroke of the corresponding press in the forging of the preform with stepped shape.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.31-35
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• 2003

Friction in cold forging with mist lubrication is measured with the ring compression test. Small quantity of mist lubricant is sprayed onto the surfaces of cemented tungsten carbide (WC) tools polished to mirror surfaces, and the specimens of pure aluminum are compressed. It is found that spraying small quantity of lubricant $(0.5\;g/m^2)$ is effective to reduce the friction in comparison with the dry condition. The mist particles stick to the tool surface as separated dots, and the behavior of the trapped mist lubricant between the tool and specimen during upsetting is discussed.