• 소성∙가공
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• 제12권6호
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• pp.572-581
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• 2003

In this paper, an automatic surface construction method based on B-spline surface and scalar field theory is proposed to generate the extrusion die surface of non-symmetric H-and U-shaped sections. The isothermal lines and stream lines designed in the scalar field are introduced to find the control points which are used in constructing B-spline surfaces. Intersected points between the isothermal lines and stream lines are used to construct B-spline surfaces. The inlet and outlet profiles are precisely described with B-spline curves by using the centripetal method for uniform parameterization. The extrusion die surface is generated by using the cubic curve interpolation in the u-and v-directions. A quantitative measure for the control of surface is suggested by introducing the tangential vectors at the inlet and outlet sections. To verify the validity of the proposed method, automatic surface generation is carried out for extrusion die of non-symmetric H-and U-shaped sections.

• Design & Manufacturing
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• 제7권1호
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• pp.11-18
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• 2013

This paper presents the plastic inhomogeneous deformation behavior of bimetal composite rods during the axisymmetric and steady-state extrusion process through a conical die. The rigid-plastic FE model considering frictional contact problem was used to analyze the co-extrusion process with material combinations of Cu/Al. Different cases of initial geometry shape for composite material were simulated under different conditions of co-extrusion process, which includes the interference and frictional conditions. The main design parameters influencing on deformation pattern are diameter ratio of the composite components and semi-die angle. Efforts are focused on the deformation patterns, velocity gradient, predicted forming load and the end distance through the various simulations. Simulation results indicate that there is an obvious difference of forming pattern with various diameter ratio and semi-die angle. The analysis in this paper is concentrated on the evaluation of the design parameters on the deformation pattern of composite rod.

• 소성∙가공
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• 제18권3호
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• pp.210-216
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• 2009

Springback, an elastic material recovery after the unloading of stamping tools, causes variations and inconsistencies of final part dimensions. Recently, narrow and long surround molding parts around door frame are applied to high grade automobiles, but there are great difficulties in their die development, construction and tryout because of several springback modes including vertical movement and twist during flange forming process of them. So it is very important to predict springback's quantities of a surround molding part and, moreover, to compensate the die for them adequately, when they can't be corrected by the restrike operation. This paper presents a case study based on the die design for a surround molding part made of stainless steel. The forming and springback predictions, carried out using PAMSTAMP 2G, are reported and compared with the measurement data of the prototype. The predicted springback results were acceptable, so the processes of compensating die using Automatic Die Compensation Module of PAMSTAMP 2G were performed iteratively until the tolerances between the designed shape and the simulation data were satisfied.

• 한국산학기술학회논문지
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• 제11권1호
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• pp.49-54
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• 2010

자동차의 A.C 제너레이터(alternating current generator) 부품으로 사용되는 로터폴(rotor pole)을 가공할 때는 트랜스퍼온간단조금형(transfer warm forging die)으로 성형한다. 소재를 온간가공 영역으로 가열한 후 즉시 금형안으로 이송시켜 제1스테이지(1st stage)에서 업세팅가공(upsetting work)하고 제2스테이지(2nd stage)로 이송하여 측방압출(lateral extrusion)가공을 한다. 이때 측방압출 스테이지의 금형에서 다이블록(die block), 다이부싱(die bushing), 센터펀치(center punch), 사이드펀치(side punch)의 접촉면이 압출시의 과혹(過酷)한 조건에 견디지 못하여 쉽게 마멸(abrasion)되어 금형수명(die life)을 단축시키고 있다. 이 때문에 생산량 감소로 인한 납기지연, 금형의 수리보수시간 과다, 제품의 정밀도 저하 등의 문제점이 발생되고 있다. 이러한 문제점을 해결하기 위하여 금형재질 선정과 열처리 작업 싸이클 개선, 방전가공시의 트러블 해소, 핵심부품의 구조변경 등을 연구하여 금형수명을 40~50% 연장 하고자 하였다.

• 소성∙가공
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• 제9권4호
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• pp.362-371
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• 2000

In order to reduce weight of a high-speed railroad vehicle, the main body has been manufactured by hollow section extrusion using aluminum alloys. A porthole die has utilized for the hollow section extrusion process, which causes complicated die geometry and flow characteristics. Design of porthole die is very difficult due to such a complexity. The three-dimensional finite element analysis for hollow section is also an arduous job from the viewpoint of appropriate mesh construction and tremendous computation time. In the present work, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain, is implemented for the analysis of the hollow section extrusion process. In addition, a modified grid-based approach with the surface element layer is utilized lot three-dimensional mesh generation of a complicated shape with hexahedral elements. The effects of porthole design are discussed through the simulation for extrusion of an underframe part of a railroad vehicle. An experiment has also been carried out for the comparison. Comparing the velocity distribution at the outlet with the thickness variation of the extruded part, it is concluded that the analysis results can provide reliable measures whether the die design is acceptable to obtain uniform part thickness. The analysis results are then successfully reflected on the industrial porthole die design.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 추계학술대회논문집
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• pp.318-321
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• 2003

In order to generate the extrusion die surface of non-symmetric H- and U-shaped sections, an automatic surface construction method based on B-spline surface and scalar field theory is proposed in this study. The isothermal lines and stream lines designed in the scalar field are introduced to find the control points which are used in constructing B-spline surfaces. Intersected points between the isothermal lines and stream lines are used to construct B-spline surfaces. The inlet and outlet profiles are precisely described with B-spline curves by using the centripetal method for uniform parameterization. The extrusion die surface is generated by using the cubic curve interpolation in the u- and v-directions. A quantitative measure for the control of surface is suggested by introducing the tangential vectors at the inlet and outlet sections.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 추계학술대회논문집
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• pp.197-200
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• 2003

An automatic surface construction method based on B-spline surface and scalar field theory is proposed to generate the extrusion die surface of complicated sections in this paper. The isothermal lines and stream lines designed in the scalar field are introduced to find the control points which are used in constructing B-spline surfaces. Intersected points between the isothermal lines and stream lines are used to construct B-spline surfaces. The inlet and outlet profiles are precisely described with B-spline curves by using the centripetal method for uniform parameterization. The extrusion die surface is generated by using the cubic curve interpolation in the u- and v-directions. A quantitative measure for the control of surface is suggested by introducing the tangential vectors at the inlet and outlet sections.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 제4회 박판성형 심포지엄
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• pp.41-52
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• 2003

The tendency of current die manufacturing is focusing into development period shortening and panel quality improvement. This brings change of manufacturing process. In existing process, depended on experience, we were faced on a limit of sufficiency in this focus. Thus, we have attempted to make a conquest of that by constructing a process of CAE. Our attempt apply not only draw die formability but also trimming and flanging die formability with simulation of sheet metal. In this paper, we publish effects that were obtained by constructing a process.

• 소성∙가공
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• 제13권1호
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• pp.33-38
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• 2004

A new approach for the design of extrusion die surface of arbitrarily shaped section is presented. In order to generate the extrusion die surface. an automatic surface construction method based on B-spline surface and scalar field theory is proposed. The isothermal lines and stream lines designed in the scalar field are introduced to find the control points which are used in constructing B-spline surfaces. Intersected points between the isothermal lines and stream lines are used to construct B-spline surfaces. The inlet and outlet profiles are precisely described with B-spline curves by using the centripetal method for uniform parameterization. The extrusion die surface is generated by using the cubic curve interpolation in the u- and v-directions. A quantitative measure for the control of surface is suggested by introducing the tangential vectors at the inlet and outlet sections. To verify the validity and effectiveness of the proposed method, automatic surface generation is carried out for extrusion dies of arbitrarily shaped sections.

• 한국정밀공학회지
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• 제9권1호
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• pp.96-105
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• 1992

A study on the construction of a CAD/CAM system operated by 16 Bit PC basic language, for machining sculptured surface of die, was carried out. The system consists of 2 steps i.e., process for geometric modelling by wire frame and process for machining data generation. Geometric modelling for sculptured surface is made by the point data fitting, parallel sweeping, normal sweeping and linear connection of cross section curve. Machining data are gained by cutter off-set of geometric model data and machining carried out by DNC. This system is to be proved enough for rough cutting by actual machining experiment. But, for becoming a high level system, another method of cutter off-set has to be regarded and system must be reconstructed by another program language.