• Title/Summary/Keyword: Die Material

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Flexible Forming Process Analysis for Sheet Material Curved Surface Forming (박판소재 곡면성형을 위한 가변성형공정 해석)

  • Seo, Y.H.;Heo, S.C.;Ku, T.W.;Kim, J.;Kang, B.S.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2008.10a
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    • pp.118-121
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    • 2008
  • Flexible die is more efficacious than fixed die which is generally used in stretch forming process in view of production cost. Accordingly, in order to verily the validity of the flexible forming process, curved thin skin structure forming analyses using the fixed and flexible die were performed. As results, merit and demerit with regard to the fixed and flexible die were confirmed. The result of the stretch forming process analysis using the flexible die was better than that using the fixed die in view of the elastic recovery. However wrinkles were occurred on the sheet material due to die cavities between the punches in the flexible forming process, thus the solutions against these problems were presented.

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A Study on the Formability Factors of Axisymmetric Multi-Stage Deep Drawing Processes (축대칭 다단계 딥드로잉 공정의 성형인자에 대한 연구)

  • 여은구;조선형;이용신
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.11 no.4
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    • pp.6-11
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    • 2002
  • Formability in deep drawing process depends not only on a drawability of workpiece material but also on process conditions such as die punch comer radius, lubricant conditions, punch-die clearance etc. For instance, bending resistance should be reduced by increasing die round appropriately, drawing load should be minimized by improving the lubricant condition between die and material, and blanking load should be increased by selecting a pertinent punch round and by augmenting the friction resistance in punch. In this study, a multi-stage deep drawing process is analyzed using ABAQUS. The effects of formability factors, such as die shoulder radius, punch-die clearance and friction coefficient are investigated, and the results are also discussed in detail.

A Study on the Design of the Prestressed Precision Cold Forging Die (예압된 정밀 냉간단조 금형설계에 관한 연구)

  • Yeo, H. T.;Choi, Y.;Hur, K. D.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2000.11a
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    • pp.377-380
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    • 2000
  • The dimensional accuracy of the cold forged part is depended on the elastic characteristics of the die. To obtain the high stiffness of the prestressed die, the first stress ring of the tungsten carbide material is considered. For the design, Lam 's equation is used. The design of the prestressed die has been compared with the conventional that. For the comparison, the FE-analysis using ANSYS has been performed. The results indicate that the prestressed die with the high stiffness can be obtained by the using the high stiffness material as the first stress ring.

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Development of Adjust Plate Progressive Die (자동차용 Adjust Plate Progressive 금형 개발)

  • Bae, Yong-Hwan;Ban, Gab-Su
    • Journal of the Korean Society of Safety
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    • v.17 no.4
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    • pp.1-4
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    • 2002
  • A automatic production system was developed for high productivity and safety. The semi-progressive die was unfavorable for more productivity, safety, material extravagance and incongruent high-speed production. Developed progressive die is suitable for the high production and guarantee triple production by acceptance of three array type for automobile adjust plate. We adopt Pro-$Engineer{\circledr}$ for three dimensional computer aided design suitable for the disassembly and assembly evaluation. The conclusion of this study is as follow. First, press die parts solid modeling system is built by using Pro-$Engineer{\circledr}$ through this research and verified allowable tolerance and possibility of assembly and disassembly of parts. Therefore we can reduce die manufacturing time and cost. Second, We produce 1000 units pet hot coil 1ton by traditional method, but we can acomplish material saving effect about 12% as 120 units in case of new progressive die. Fourth, we acomplished manufacturing cost curtailment effect more than 20% in comparison with traditional method.

Study on Application of Flexible Die to Sheet Metal Forming Process (가변금형의 박판 성형공정 적용 연구)

  • Heo, S.C.;Seo, Y.H.;Ku, T.W.;Kim, J.;Kang, B.S.
    • Transactions of Materials Processing
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    • v.18 no.7
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    • pp.556-564
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    • 2009
  • Flexible forming process for sheet material using reconfigurable die is introduced based on numerical simulation. In general, this flexible forming process using the reconfigurable die has been utilized for manufacturing of curved thick plates used for hull structures, architectural structures and so on. In this study, numerical simulation of sheet metal forming process is carried out by using flexible dies model instead of conventional matched die set. The numerical simulation and experimental verification for sheet metal forming process using a flexible forming machine that is more suitable for thick plate forming process are carried out to confirm the appropriateness of the simulation process. As an elastic cushion, urethane pads are utilized using hyperelastic material model in the simulation for smoothing the forming surface which is discrete due to characteristics of the flexile die. In the flexible forming process for sheet metal, effect of a blank holder is also investigated according to blank holding methods. Formability in view of occurrence of dimples is compared with regard to the various punch sizes. Consequently, it is confirmed that the flexible forming for sheet material using urethane pad has enough capability and feasibility for manufacturing of smoothly curved surface instead of conventional die forming method.

The Hot Forging of Small Size Gas Turbine Disks (소형가스터빈 디스크의 얼간단조)

  • Cha, D.J.;Song, Y.S.;Kim, D.K.;Kim, Y.D.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2008.10a
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    • pp.370-373
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    • 2008
  • Small size gas turbine disk requires good mechanical strength and creep properties at high temperature. In this study, Waspaloy was used as a superalloy to satisfy these specifications. The control of microstructure was needed to satisfy material properties at high temperature. In order to do this, we studied forging conditions and material analysis. Therefore die and preform design conducted so that hot forged gas turbine disk could have a good microstructure. The die and preform shapes are designed with consideration of the predefined hydraulic press capacity and the microstructure of forging product. Also we carried out the hot compression test for Waspaloy in various test conditions. From these results, we obtained the forging conditions as material temperature, die velocity etc. To verify these forging conditions, we conducted FE simulations by means of the DEFORM 2D-HT. In this study, the hot closed die and preform designs were completed to offer high temperature material properties of a small size gas turbine.

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An Influence of the Frictional Condition on Material Flow in Forward/Backward Combined Extrusion Process (전/후방 복합 압출공정에서 마찰조건이 재료 유동에 미치는 영향)

  • Kim, M.T.;Noh, J.H.;Hwang, B.B.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2009.10a
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    • pp.433-436
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    • 2009
  • This study is concerned with an effect of frictional condition in a forward/backward combined extrusion process. Generally, the material flow of the billet is influenced by the corners of the die cavity, the ratio in reduction in area, and thickness ratio of backward can thickness to forward can thickness. In addition, the frictional condition in contact area between the billet and the punch/die also affect the material flow. This paper investigated the effect of frictional condition for variable friction factors. The FEM simulation has been carried out in order to examine the effect of frictional condition. Deformation patterns and flow characteristics were examined in terms of design parameters such as extruded length ratio etc. Die pressure exerted on the die-workpiece interface is calculated by the simulation results and analyzed for safe tooling. Therefore the numerical simulation works provide a combined extrusion process of stable cold forging process planning to avoid the severe damage on the tool.

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A Study on the Forming Characteristics of Radial Extrusions (레이디얼압출의 성형특성에 관한 연구)

  • 이수형;황병복
    • Transactions of Materials Processing
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    • v.8 no.6
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    • pp.604-611
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    • 1999
  • This paper is concerned with the family of parts that generally feature a central hub with radial protrusions. As opposed to conventional forward and backward extrusion, in which the material flows in a direction parallel to that of the punch or die motion, the material flows perpendicular to the punch motion in radial extrusion. Three variants of radial extrusion of a collar or flange are investigated. Case I involves forcing a cylindrical billet against a flat die, Case II involves deformation against a stationary punch recessed in the lower die, and Case III involves both the upper and lower punches moving together toward the center of the billet. Extensive simulational work is performed with each case to see the process conditions in terms of forging load, balanced and symmetrical flow in the flange. Also, the effect of the gap size and die corner radii to the material flow are investigated. In this study, the forming characteristics of radial extrusion will be considered by comparing the forces, shapes etc. The design factors during radial extrusion are investigated by the rigid-plastic FEM simulation.

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Fabrication and Characteristics of a Piezoelectric Valve for MEMS using a Multilayer Ceramic Actuator (적층형 세라믹 엑추에이터를 이용한 MEMS용 압전밸브의 제작 및 특성)

  • 정귀상;김재민;윤석진
    • Journal of the Korean Institute of Electrical and Electronic Material Engineers
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    • v.17 no.5
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    • pp.515-520
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    • 2004
  • We report on the development of a Piezoelectric valvc that is designed to have a high reliability for fluid control systems, such as mass flow control, transportation and chemical analysis. The valve was fabricated using a MCA(multilayer ceramic actuator), which has a low consumption power, high resolution and accurate control. The fabricated valve is composed of MCA, a valve actuator die and an seat die. The design of the actuator dic was done by FEM(finite element method) modeling, respectively. And, the valve seat die with 6 trenches was made. and the actuator die, which possible to optimize control to MCA, was fabricated. After Si-wafer direct bonding between the seat die and the actuator die, MCA was also anodic bonded to the scat/actuator die structure. PDMS(poly dimethylsiloxane) sealing pad was fabricated to minimize a leak-rate. It was also bonded to scat die and stainless steel package. The flow rate was 9.13 sccm at a supplied voltage of 100 V with a 50 % duty ratio and non-linearity was 2.24 % FS. From these results, the fabricated MCA valve is suitable for a variety of flow control equipments, a medical bio-system, semiconductor fabrication process, automobile and air transportation industry with low cost, batch recess and mass production.

Analysis of Springback and Die Material Suitability in the UHSS Sheet Forming Process (초고강도 강판 성형 시의 스프링백 해석 및 금형 소재 적합성 검토)

  • Oh, I.S.;Yun, D.Y.;Cho, J.H.;Lee, M.G.;Kim, H.Y.;Kim, H.J.
    • Transactions of Materials Processing
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    • v.29 no.4
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    • pp.203-210
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    • 2020
  • In this study, formability and springback behavior of 1.5 GPa grade ultra-high strength steel (UHSS) sheet were predicted through the finite element simulation, and structural stability of the forming dies was verified by the coupled forming-structural analysis. Uniaxial tension and uniaxial tension-compression tests were performed to obtain experimental data for modeling the springback properties of the sheet material. The springback values predicted by simulation were compared with those from actual measurements. The results calculated from the kinematic hardening model were found to be much more accurate than those from the isotropic hardening model. Deformation of the forming die and springback of the product were calculated by the coupled forming-structural analysis. The higher the strength of the die material, the smaller the surface displacement of the die and the springback of the product. The internal stresses of the dies made of three materials, FC300, FCD550 and STD11 were compared with the yield stress of each material. The results provided a basis for determining the most suitable material for each part of the die set. As a result, simulation techniques have been established for predicting formability and springback in the UHSS sheet forming process.