• Title/Summary/Keyword: Die Angle

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A Study for Preventing Folding Defect of the Common Rail Pipe in Heading Process (커먼레일 파이프 헤딩공정의 접힘결함 방지에 관한 연구)

  • Song, Myung-Jun;Woo, Ta-Kwan;Jung, Sung-Yuen;Hur, Kwan-Do;Kim, Chul
    • Journal of the Korean Society for Precision Engineering
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    • v.27 no.1
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    • pp.25-32
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    • 2010
  • With the latest automobile technology, though the third generation common rail system requires high injection pressures up to 1,800bar, the next generation diesel engine is expected to require more higher pressures than the third generation. The common rail pipe requires higher strength because it is one of the parts in the common rail system, which is influenced directly by fuel under high pressure. Preform design is very important for preventing head of the common rail pipe from folding in the heading process. In this study, die angle, curvature, outer diameter of die and length of trapped part are selected as main parameters to obtain best preform shape minimizing radius of folding. Therefore optimal design is carried out by finite element analysis and Taguchi method through main parameters. Results of the finite element analysis have good agreements with those of the experiments in the actual field.

The Development of Seat Track Parts Using Shape Freeze in UHSS (초고강도 소재 성형시 형상 동결을 이용한 Seat Track 부품 개발)

  • Park, Dong Hwan;Yun, Jae Jung;Moon, Hyun Duk;Lee, Tae Gil
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.26 no.1
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    • pp.59-65
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    • 2017
  • A seat track product is a car seat part that provides a base for vehicle seats. An ultra-high strength steel sheet is used to reduce the weight of vehicle body parts. However, the formability of an ultra-high strength steel sheet is poor because of its very low elongation and very high elastic deformation. For this reason, a new forming technology of an ultra-high strength steel sheet is required. The influence of spring-back of seat track parts on the shape freeze in forming processes was investigated to be solved by adjusting the appropriate tool design such as minus clearance between punch and die, and punch angle. This paper describes how to apply the spring-back prevention technique for improving shape freeze by using the ultra-high strength steel sheet with 980MPa to develop lightweight seat tract parts.

A Study on the Forming Characteristics of Forward and Backward Extrusions (전.후방 캔 압출공정의 성형특성 연구)

  • Shim Ji-Hun;Choi Ho-Joon;Ok Jeong-Han;Ham Byoung-Soo;Hwang Beong-Bok
    • Journal of the Korean Society for Precision Engineering
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    • v.22 no.3 s.168
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    • pp.86-92
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    • 2005
  • In this paper a forward-backward can extrusion process are analyzed by using rigid-plastic FEM simulation. FEM simulation is conducted to investigate forming characteristics such as deformation modes fur different process parameters. Design parameters such as thickness ratio, punch angle, friction factor and diameter ratio are selected to study the effect of them on the pattern of material flow. The analysis is focused mainly on the influences of the design factors on deformation pattern in terms of forming load, extruded length ratio and volume ratio. It is known for the simulation that the forming load, the length ratio and the volume ratio increase as the thickness ratio (TR), the wall thickness in forward direction to that in backward direction, decreases. The various punch angles have slight influence on the forming load. length ratio and volume ratio. However friction factor have little effect on the forming characteristics such as the forming load, volume ratio and so on. In addition the forming load increases as diameter ratio (DR), the outer diameter of a can in forward direction to that in backward direction, increases. Furthermore the extruded length ratio is lowest with a certain value of DR=0.85 among diameter ratios. Pressure distribution exerted on the die-material interface is illustrated schematically.

Development of Discharge Electrode for Machining Connector Mold applying MIM Process (MIM 공법 적용 커넥터 금형 가공용 방전 전극 개발)

  • Shin, Kwang-Ho;Jeon, Yong-Jun;Heo, Young-Moo
    • Design & Manufacturing
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    • v.8 no.2
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    • pp.37-40
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    • 2014
  • A discharge electrode plays a role of shaving off workpiece with spark generated by current in discharge machining. Accordingly, for the discharge electrode, an electrode with excellent wear resistance is necessary. Generally, Graphite and Cu are used as the materials of the electrode, and recently Cu-W is mainly used as an electrode with excellent wear resistance. However, the form of the electrode generally used is produced mostly using cutting work, so a lot of costs incur if several similar forms are needed. Thus, this study developed a Cu-W electrode using Metal Injection Molding (MIM) process to produce similar forms with excellent productivity and a great quantity of electrodes in a similar form in discharge machining and carried out a discharge machining test. In developing an electrode applying MIM, predicting contraction of a product in a sintering process, a mold expansion ratio of 1.29486 was given, but the actual product showed a percentage of contraction 24% to 32%, which showed a difference of 3% to 5%. In addition, to verify wear resistance of the discharge electrode, abrasion loss was measured after the discharge.

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Study of Turbine Module Design for Die Casting Mold Release Injection Robot System (다이케스팅 이형재 분사 로봇시스템의 터빈 모듈 설계에 관한 연구)

  • Choi, Hyun-Jin;Son, Young-Bum;Park, Chul-Woo;Lee, Seung-Yong;Choi, Seong-Dae
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.14 no.5
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    • pp.1-7
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    • 2015
  • Cleaning by injecting dry ice and water is a generally adopted trend these days to clean molds (injection, diecasting foundry, press, rubber mold, etc). This cleaning method is performed manually, or by installing multiple high pressure spray nozzles. We have manufactured a turbine cleaning module device that is able to clean diecasting modules at any position and angle in the space by mounting an articulated robot instead of the existing pipe type injection nozzle, to minimize lead time and enhance working yield of the cleaning process. In this paper, we analyzed process factors that are required to design the turbine module by reviewing number of revolution, and results according to different blade angles and thicknesses of the mold release injection turbine module, using computational fiuid dynamics (CFD).

Characteristics of Ball End Milling and Rotary Die-sinking Electrical Discharge Machining for the Cutting Inclination Location (가공경사면 위치에 따른 볼엔드밀가공과 회전식 형조방전가공 특성)

  • 왕덕현;김원일;박성은;박창수
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.11 no.5
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    • pp.73-80
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    • 2002
  • In this study, work materials of the ree form surface shape was machined by ball end mill cutter according to the change of cutting location and depth, and the acquired data of cutting force, tool deflection and shape accuracy were analyzed. Cutting force results were obtained with tool dynamometer and tool deflection values were measured by a couple of eddy-current sensors. Shape accuracy was obtained by roundness tester and surface profile measuring machine. As inclination angle was decreased, cutting force was increased. Cutting force showed large value at $105^{\circ}$ and $150^{\circ}$. Tool deflection was less at down milling than at up milling, decreased at 45$^{\circ}$ and 120$^{\circ}$, and shown large tool deflection at $150^{\circ}$. Roughness values were found to be bad in the inside of surface shape tool deflection. Surface accuracy was obtained better precision in down milling than in up milling.

Process Map for Improving the Dimensional Accuracy in the Multi-Stage Drawing Process of Rectangular Bar with Various Aspect Ratio (다양한 종횡비의 직사각바 다단 인발공정에서 치수정도 향상을 위한 프로세스 맵)

  • Ko, P.S.;Kim, J.H.;Kim, B.M.
    • Transactions of Materials Processing
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    • v.27 no.3
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    • pp.154-159
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    • 2018
  • In the rectangular bar multi-stage drawing process, the cross-section dimensional accuracy of the rectangular bar varies depending on the aspect ratio and process conditions. It is very important to predict the dimensional error of the cross-section occurring in the multi-stage drawing process according to the aspect ratio of the rectangular bar and the half die angle of each pass. In this study, a process map for improving the dimensional accuracy according to the aspect ratio was derived in the drawing process of a rectangular bar. FE-simulation of the multi-stage shape drawing process was carried out with four types of rectangular bar. The results of the FE-simulation were trained to the nonlinear relationship between the shape parameters using an Artificial Neural Network (ANN), and the process maps were derived from them. The optimum half die angles were determined from the process maps on the dimensional accuracy. The validity of the suggested process map for aspect ratios 1.25~2:1 were verified through FE-simulation and experimentation.

An Experimental Study for Mechanical Properties of Al-Mg-Mn-Si Alloy by ECA pressing (ECA기법을 활용한 Al-Mg-Mn-Si 합금의 기계적 성질에 관한 연구)

  • Kook, Jong-Han
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.20 no.6
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    • pp.785-792
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    • 2011
  • Equal channel angular(ECA) pressing is the established processing technique in which a polycrystalline metal is pressed through the die to achieve a very high plastic strain. Therefore, the capability to produce an ultra-fine grain size in the materials is provided. To investigate that mechanical properties at elevated temperature have the ultrafine grain ECA pressing, experiments were conducted on an Al-4.8% Mg-0.07% Mn-O.06% Si alloy. After having been solution treated at 773K for 2hrs, the billet for ECA pressing was inserted into the die. And it was pressed through two channel of equal to cross section intersecting at a 90 degree angle. The billet can be extrude repeatedly because of 1:1 extrusion ratio. Since the billet is passed through the cannel for 2 times, a large strain is accumulated in the alloy. The tensile tests on elevated temperature were carried out with initial strain rate of $10^{-3}s^{-1}$ at eight temperature distributed from 293K to 673K.

The Direct Extrusion of Copper Clad Aluminum Composite Materials by Using the Conical Dies (원추형 다이를 이용한 Cu-Al 층상 복합재료의 직접압출)

  • Yun, Yeo-Gwon;Kim, Hui-Nam
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.25 no.10
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    • pp.1541-1550
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    • 2001
  • This paper describes experimental investigations in the direct extrusion of copper clad aluminum rods through conical dies. Composite materials consist of two or more different material layers. Copper clad aluminum composite materials are being used fur economic and structural purposes and the development of an efficient production method of copper clad aluminum composite material rods by extrusion is very important, It is necessary to know the conditions in which successful uniform extrusion ,and sound cladding may be carried out without any defects in the direct extrusion. There are several variables that have an influence on determining a sound clad extrusion. In order to investigate the influence of these parameters on the hot direct extrudability of the copper clad aluminum composite material rods, the experimental study have been performed with various extrusion temperatures, extrusion ratios and semi-cone angles of die. Subsequently, the microscopic inspection of interface bonding is carried out for extruded products. By measuring hardness, along extrusion way of products, a variation of hardness has been discussed. Proportional flow state has been considered by measuring radius ratio of Cu sleeve and Al core before and after extrusion.

Analysis of impingement mixing for coating in injection mold (사출금형 안에서 코팅을 위한 충돌혼합에 관한 해석)

  • Kim, Seul-Woo;Lee, Ho-Sang
    • Design & Manufacturing
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    • v.13 no.4
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    • pp.1-9
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    • 2019
  • In-mold Coating is a method that can simultaneously perform injection molding and surface coating in injection mold. The material used for coating is two-component polyurethane which is composed of polyol and isocyanate. L-type mixing head can be used to mix polyol and isocyanate uniformly, and inject them inside the mold cavity. The surface quality of the injection molded products by using in-mold coating depends on the mixing uniformity between main agent and hardener. In this study, flow analysis was performed to design a mixing head for uniform mixing of two-component polyurethane. Especially the effects of design parameters of mixing head on mixing uniformity and nozzle pressure were investigated. The parameters of mixing head were mixing chamber diameter, cleaning cylinder diameter, nozzle alignment angle in the horizontal and vertical direction, and cleaning piston position. It was found that optimal design values were mixing chamber diameter of 3.5 mm, cleaning cylinder diameter of 5.0 mm, nozzle horizontal/vertical alignment angles of 140°/160°, and cleaning piston position of 1.8 mm. The optimal values would be used to develop a two-component mixing head achieving an uniform mixing for in-mold coating.