• Transactions of Materials Processing
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• v.4 no.4
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• pp.335-344
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• 1995

In this paper, an experimental study of a hot forging process is carried out using plasticine and the die set manufactured with the aid of rapid prototyping. In order to manufacture the die set, Stereolithography Apparatus(SLA) which is most widely used rapid prototyping system is introduced. Turbine blade forging is performed using palsticine and the SLA prototype die set. Through the experiment, it has been shown that SLA prototype is suitable to the die set for the plasticine workpiece, and the formability and the forming load of turbine blade forging are predicted.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.1
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• pp.117-122
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• 2001

Many kinds of channels are used in industrial equipment and production machinery. Although mechanical saw has been used to cut many sorts of channels, there is cost rise problem because of low productivity. Shearing of channel has a special place because it helps to cut expected shape and size easily. A channel cutting die set which can be mounted and used on a hydraulic press is developed to improve the productivity of channel cutting process. Mode for the channel cutting is divided into single cut and double cut method. This study use double cut method, and the developed channel cutting die set is composed of upper and lower die set. Shearing time can be reduced from 40 minutes to 20 seconds using the developed channel cutting die set. The productivity of channel cutting process can be increased with shearing time reduction as well as cost reduction.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.9
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• pp.32-40
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• 2004

This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. The system is composed of four main modules. The process planning and the die design modules consider several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

• Transactions of Materials Processing
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• v.9 no.5
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• pp.533-538
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• 2000

This study has been carried out to develop a CRT die using hot forging. The conventional CRT die made by casting has defects such as void and inclusion. These defects of the cast die make micro-spots on the surface of the CRT which affect the quality of the final product. So, a hot forging process is developed to avoid these defects of CRT die by the model material test and the rigid-plastic FEM. Firstly, model material tests are carried out with plasticine billets in order to investigate the material flow pattern in the die cavity and to get the reasonable initial values for designing the preform in the FE simulation. And then a finite element analysis has been performed to Predict the preform and the forging load of a CRT die. We also suggest an integrated die-set which combines two die-sets into one die-set to save manufacturing time and cost in case of similar die-size.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.363-370
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• 2002

In this study, an optimal design technique was investigated for determining appropriate dimensions of components of the die set used in the extrusion process. For this, an axi-symmetric elastic finite element program for the analysis of deformation of the shrink fitted die set was developed with the Lagrange multiplier method to implement the constraint condition of shrink fit of stress ring. By coupling the rigid-viscoplastic analysis of extrusion process by CAMPform and elastic analysis of the die set, the optimization study was made by employing optimization program DOT. Considering the various assembly conditions, optimal design was determined for a single stress ring case. It is construed that the proposed design method can be beneficial for improving the tool life of cold extrusion die set at practice.

• Transactions of Materials Processing
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• v.20 no.3
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• pp.206-213
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• 2011

A flexible die, which is composed of a number of punches with adjusted heights to form a three-dimensional curved surface, is a crucial part of a flexible forming technology. In this study, the punch and control system of the flexible die were designed. The flexible die is divided into three modules, namely, punch, control and joint, and the corresponding modules were developed. The punch module materializes a three-dimensional forming surface by the control module, which is composed of an AC servo motor set and a linear guide. The joint module is necessary for the sequential motion between the servo motor set and the punch module. A sequential motion algorithm for the AC servo motor set, that uses the data of the punch relative heights, was also proposed. Finally, a flexible stretch forming test was carried out using the presently designed flexible die.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.11
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• pp.74-80
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• 1999

In this study, a stereolithography apparatus (SLA) prototype is used as a master model to be transformed into the silicone pattern by vacuum tool forming. The tool for the first prototype is fabricated by using this silicone pattern. Following this procedure, a temporary tool with metal powder and epoxy for wax injection is prepared for the die set of quick change type which consists of upper and lower base die나 and an insert die. The die set of quick change type appears to be very effective in casting operation by changing tools rapidly. The original wax pattern is formed through the die set, and is made of lost-was. Finally the lost-wax pattern is applied to investment casting. The final casting product is checked regarding its dimensional accuracy.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1307-1311
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• 2004

This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.1
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• pp.7-15
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• 2008

Currently existing high-accuracy and high-speed die sets used in reciprocal press create scratches at the surface of guide posts, steel balls, and bushes due to vertical movement of balls with point-contacts between inner surface of bushes and guide posts. Consequently, accuracy of the die set and the life span of the metal mold are reduced. However, those scratches could reduce the pre-load of the steel ball. This research designed and developed a groove-type die set which improves life span of the die set by eliminating point-contacts of steel balls with guide posts. The guide post consisted of a steel-ball retainer, a steel-ball retainer stopper, a guide bush, a guide pin, a snap ring, and a spring. The steel-ball retainer has 72 holes with 8 columns of 9 holes in each column. The inner surface of the guide bush was grinded(surface roughness: $Ra\;\\;0.2{\mu}m$, accuracy: $0\;{\sim}\;-0.002mm$) after NC turning and heat treatment. Also, a line of small intermediate pocket was processed inside of the guide bush for lubrication and elimination of foreign materials. Guide grooves of steel balls were processed using a wire EDM(Electrical Discharge Machining) after heat treatment. With such a design of the guide post stated above, loads against steel balls could be dispersed greatly by the line contacts through the guide groove between the guide post and the guide bush, and the life span of the guide post could be expanded semi-permanently.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.17-23
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• 2008

Development of die technology for holder and barrel dies is necessary according to minimization of lens assembly, image sensor, and connectors. In these cases, there are two technical problems arising from die design. One is determination of knock-out pin location in die set. Minimization of lens assembly size make it difficult to obtain ejecting space. The other is whether or not high-precision die technology is possible to reduce torque variation when holer and barrel products is assembled. In this study, multi-cavity die set was developed taking advantage of gear-driven ejecting method. In the developed technology, die manufacturing technology was guaranteed with a high-precision level.