• Transactions of Materials Processing
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• v.16 no.7
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• pp.538-548
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• 2007

In this paper, a novel approach which enables rapid die surface modification for sheet metal forming process is proposed. In this method an implicit surface which interpolates a given set of control points and displacement constraints is generated to compute the displacements at arbitrary points located on die surface. The proposed method does not depend on the underlying surface representation type and is affected neither by its complexity nor by its quality. In addition, the domain decomposition method is introduced in order to treat large surface model. The global domain of interest is divided into smaller domains where the problem can be solved locally. And then the local solutions are combined together to obtain a global solution. In order to verify the validity and effectiveness of the proposed method, various surface modifications are carried out fur three kinds of die surface model including polygonal surface composed of triangular and rectangular meshes, polynomial surface and NURBS surface.

• 연구논문집
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• s.26
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• pp.121-132
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• 1996

The carburising surface modification treatment of the die steel has been used for improving wear resistance and heat cycle strength of the die and preventing a pitting on the surface because the carbides are forming in the matrix during carburising. Generally, the hot forging die was used after quenching-tempering treatment or nitriding after quenching-tempering treatment. The nitriding after carburising on the surface of a hot die steel and a wear resistance die steels was suggested by SOUCHARD, JACQUOT. and BUVRON. This surface modification treatment improved the adhesive and abrasive wear resistance and friction coefficient. The process was introduced to the forging die of stainless steel, titanium alloy steel, alloy and medium carbon steel and the physical properties of the die after the treatment were improved. The surface hardening treatment of the nitriding, the carburising, the boriding, and TD process were used to improved the life time of the forging die. Also, the coating process of PVD, CVD and PCVD were used and the hard chromium plating was occasionally used. Therefore, this study analyzed the effects of the carburising time and the conditions of nitriding on STD61 steel. The case depth, the surface hardness, the forming carbide size and shape during overcarburising process on the die steel were also examined.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.624-627
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• 2000

This paper describes a local modification capability on shell meshes, which can change a 'constant or variable radius of rounding for the s h q edges of the stamping die shoulder in the mesh. The algorithm consists of the followin_e three main steps; (1) the rounding area for sharp edges of a die shoulder are detected from the given shell mesh, (2) a rolling-ball surface with a given constant or variable radius is generated, which is contacti% with two incident face groups of the sharp edges, (3) the rounding area of the mesh is cut off, and a new mesh for the rolling-ball surface is generated and implanted into the gap. Owing to this rounding modification capability, CAE engineers can examine various cases based on the existing dies by scanning them to form polyhedral models and then changing radii of die shoulders for stamping process simulation.

• 제어로봇시스템학회:학술대회논문집
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• 1988.10a
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• pp.273-278
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• 1988

This paper represents the computer application techniques of initial and modification machining for dies with 3-dimensional scluptured surfaces. All procedures from die design to die machining and measurement are covered. The component of modelling is data management and modification (extrapolation and smoothing), surface modelling, and nc program preparation. Also this paper introduces the utility for successful and efficient operation of system such as map generation, data communication, tool path verification, contour map generation, graphic processing of extrapolation and smoothing results, and CAD/CAM system interface. Examples are given to illustrate the modelling.

• Transactions of Materials Processing
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• v.14 no.2 s.74
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• pp.153-159
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• 2005

Design modification of the stamping die for the upper member of a front end module carrier is carried out in order to improve the surface quality of the final product. The small inferiority induced by wrinkling near the wall of the upper member has been inspected after the draw-forming process. The finite element analysis is pursued with the whole geometry in order to consider the complicated shape. The simulation shows that the excess metal is developed by the irregular contact of the blank the tool and it remains after the final stroke. This paper proposes two guidelines for the modification. One is to add the draw-bead near the critical region in order to increase the draw-in force. The other is to modify the tool shape such as the forming shape at the wall in order to absorb the excess metal before the final stroke. Simulation results show that the proposed guidelines both guarantee the improved surface quality.

• Design & Manufacturing
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• v.6 no.1
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• pp.24-28
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• 2012

Friction and wear affect all processes involved in the extraction of materials and their conversion into finished products in the die applications such as drawing, extrusion etc. Originating phenomenon from the contact surface between the tool and workpiece, they are usually a hindrance to materials process operations which usually result in damaging the tools, increasing energy consumption, the contamination of processed material by wear particles and also some problems associated with technologies to control friction and wear. The most well established method to control friction and wear is by the application of lubricant such as fluorocarbon. Besides, a surface technique so-called surface modification can be applied to solve the tribology problems of the die applications for both the economical and ecological reasons. In this article, we applied DLC(diamond-like carbon) thin film on alumina ceramic for HT test using the PIID(plasma ion immersion deposition), 4 groups of test specimens were tested up to $200^{\circ}C$ which is a little higher than the normal working temperature of die application. Pin-on-disc tribo-tester was used to test the friction and surfaces were characterized by SEM and EDS and else, the morphology changes of DLC coatings were studied. The present work indicated that the DLC had a great potential to reduce the friction and wear in the alumina die application without lubricants.

• Transactions of Materials Processing
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• v.17 no.4
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• pp.278-283
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• 2008

This paper concerns the die face design for a heat protect panel aided by the finite element forming analysis in order to eliminate the surface defect and to improve the surface quality. The CAE procedure of the stamping process is introduced in order to reveal the reason of surface inferiorities and to improve surface quality. Complicated shape of the product induces the surface inferiorities such as wrinkling due to the insufficient restraining force of the forming blank and the non-uniform contact of the blank with the tools. This paper proposes a new guideline for the die design which includes the modification of tool shapes and addition of the draw-beads on the tool surface for ensuring the increased the restraining force with the uniform contact condition. The effectiveness of the proposed design is verified by the forming analysis and is confirmed by the tryout operation in the press shop. The analysis and test results show that the modified process parameters such as tool shapes and draw-beads can reduce the tendency of wrinkling and improve surface quality.

• Tribology and Lubricants
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• v.31 no.2
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• pp.56-61
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• 2015

In this study, we investigated the effectiveness of an ultrasonic nanocrystal surface modification (UNSM) technique on the mechanical and wear properties of tungsten carbide (WC). The UNSM technique is a newly developed surface modification technique that increases the mechanical properties of materials by severe plastic deformation. The objective of this study was to improve the wear resistance of press die made of WC by applying the UNSM technique. We observed the microstructures of the untreated and UNSM-treated specimens using a scanning electron microscope (SEM), and energy-dispersive X-ray spectroscopy (EDX) was used to investigate the chemical composition. The SEM observations showed the pore size and the number of pores decreased after the UNSM treatment. We assessed the wear behavior of both the untreated and UNSM-treated specimens using a scratch test. The test results showed that the wear resistance of the UNSM-treated specimens increased by about 46% compared with the untreated specimens. This may be attributed to increased hardness, reduced surface roughness, induced compressive residual stress, and refined grain size following the application of the UNSM technique. In addition, we found that the UNSM treatment increased the carbon concentration to 63% from 33%. We expect that implementing the findings of this study will lead to an increase in the life of press dies.

• Journal of the Microelectronics and Packaging Society
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• v.9 no.4
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• pp.31-34
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• 2002

For the mold die sticking mechanism, the major explanation is that the silica as a filler in EMC (epoxy molding compound) wears die surface to be roughened, which results in increase of adhesion strength. As the sticking behavior, however, showed strong dependency on the EMC models based on the experimental results from different semiconductor manufacturers, chemisorption or acid-base interaction is apt to be also functioning as major mechanisms. In this investigation, the plasma source ion implantation (PSII) using $O_2, N_2$, and $CF_4$ modifies sample surface to form a new dense layer and improve surface hardness, and change metal surface condition from hydrophilic to hydrophobic or vice versa. Through surface energy quantification by measuring contact angle and surface ion coupling state analysis by Auger, major governing mechanism for sticking issue was figured out to be a complex of mechanical and chemical factors.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.3
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• pp.88-97
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• 2009

The vacuum die casting techniques can diminish the porosity of products and provide better surface appearance by the ordinary high pressure die casting process. The vacuum system can also reduce the cold laps in the die casting process and minimize the overflow pockets of the die. The vacuum system does not need high pressures to die cast compared to the ordinary die casting process, and so enables die casting of large parts for a given machine size. Parts made by the vacuum system have higher strength and more elongation than parts made by the ordinary die casting systems. In this paper, we designed and produced the Magnesium seat frames using the vacuum die casting processes. The new Magnesium seat frame was designed to satisfy safety regulations. Some safety test procedures of the seat frame were simulated by the finite element method. We obtained 10% weight reduction by design modification of seat frames compared to the current model. Flow simulations were carried out to minimize the trial and error in producing the parts. The die casted parts using vacuum systems resulted in better mechanical characteristics and no defects compared to those without vacuum systems.