• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.713-716
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• 2002

The dimensional accuracy of the cold forged products is strongly dependent on the elastic behavior of the die. The elastic deformation of the die is continuously changed during the process. Therefore, it is needed to measure the deformation of die. Strain gauges are used to measure the elastic strains in the die during cold backward extrusion process. The strain gauges are attached on the die surface and embedded at the interface between the die insert and the stress ring. In order to compare the results with the FE-analysis, the rigid-plastic FE-analysis of cold backward extrusion process using DEFORM-3D has been performed, and the analysis of elastic deformation of the die has been done by using ANSYS with non-linear contact.

• Journal of the Semiconductor & Display Technology
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• v.15 no.2
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• pp.81-86
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• 2016

Moisture vapor transmission rate (MVTR) is an important item for many applications of polymer breathable thin film. To determine the optimum values of the process parameters, it is essential to find their influence on The significance of six important process parameters namely, extruder cylinder temperature, extruder speed, extruder dies temperature, cooling roll temperature, stretching ratio, stretching roll temperature on breathable film strength of polymer extrusion was determined. Moreover, this paper presents the application of Taguchi method and analysis of variance (ANOVA) for maximization of the breathable film MVTR influenced by extrusion parameters. The optimum parameter combination of extrusion process was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that extruder speed and stretching ratio were the most influential factor on the film strength, respectively. The best results of film MVTR were obtained at higher extruder speed and stretching ratio.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.1
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• pp.34-41
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• 2021

Interventional radiology and minimally invasive surgery both require a precisely shaped microcatheter. Microcatheters are manufactured using polymer extrusion processes with a die and puller. The manufacturing parameters and die geometry greatly influence the profile of the extrudate and designing dies using a trial-and-error process is expensive and requires a lot of time. Therefore, predicting the profile of the extrudate is important for manufacturing microcatheters. This study investigates the effects of die design and geometry on the profile of the extrudate. The profiles of the extrudate are predicted using ANSYS Polyflow with respect to the different die geometries. The outer and inner diameters and wall thickness of the predicted extrudate are compared to those of a target extrudate. The die swell of melt polymer and the effect of the pulling are both examined. Optimized die designs are suggested for manufacturing the target extrudate.

• Transactions of the Korean Society of Automotive Engineers
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• v.21 no.5
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• pp.82-86
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• 2013

The automotive weather strip has the functions isolating of dust, water, noise and vibration from outside. The core of weather strip is made of steel with stiffness. By using the wire formed as the core of weather strip, weight can be reduced as much as 35% by comparing with existing steel core. For this reason, forming wire is necessary to keep the zigzag shape as it is. The deformation which is occurred during forming process can be predicted and it can be used in case of manufacturing dies through CAE. In this paper, rolling process conditions are deduced and the springback amount is predicted after rolling process by using the simulation. The springback amount of product is measured by using optical microscope, and measurement result is compared with the simulation result of springback as the same condition. The suitable gap between dies to compensate springback after rolling process is predicted through simulation and it is used for manufacturing dies.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.5
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• pp.57-63
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• 2009

Interface friction in blanking dies, cold forging and extrusion of aluminum alloys is a major cause of inefficient process. This paper describes an investigation of femtosecond laser texturing for reduction of interface friction on sliding surfaces in forming process. Femtosecond direct writing technology was used to fabricate a laser micro-machined die and to create microgroove patterns with varying size and density on metal forming dies. A systematic approach to find the optimum parameters and computer simulation comparison of friction coefficients are provided to study the relation of friction coefficients and die profiles. In metal forming tests, the effectiveness of various laser-machined patterns for enhancing interface lubrication is determined.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.2
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• pp.660-665
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• 2014

Optimization of process parameters in polymer extrusion is an important task to reduce manufacturing cost. To determine the optimum values of the process parameters, it is essential to find their influence on the elongation of polymer breathable thin film. The significance of six important process parameters namely, extruder cylinder temperature, extruder speed, extruder dies temperature, cooling roll temperature, stretching ratio, stretching roll temperature on breathable film elongation of polymer extrusion was determined. Moreover, this paper presents the application of Taguchi method and analysis of variance(ANOVA) for maximization of the breathable film elongation influenced by extrusion parameters. The optimum parameter combination of extrusion process was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that stretching ratio were the most influential factor on the film elongation. The best results of film elongation were obtained at lower stretching ratio.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.1
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• pp.59-65
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• 2004

Hollow flange-shaped parts rue widely used in transportation systems. For good quality products, in general, design of preforms and die shapes for a progressive forging process is an important issue. For the design of die shapes for the forging process of a hollow flange, computer simulations Were earned out using the rigid-plastic finite element method. Forging defects like folding were seen in the vicinity of die corners at the typical shape ratios of upper and lower dies Die shape ratios at which the forging defect could occur during the extrusion-forging process of the hollow flange were investigated. The results might be efficiently used for the proper design of perform shapes, die shapes, and forging processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.346-349
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• 2004

In the previous experimental study about extru-bending of angle product, the bending of extruded angle products with the '${\wedge}$' section and 'ㄱ' section can be abtained by the hot metal extru-bending machine with the two punches moving in the different velocity. The bending curvature can be controlled by the different velocity of billets through the two-hole container. This paper describes simulation of extru-bending process by the difference of punch velocities. The result of the forming simulation by $DEFORM^{TM}-3D$ shows that the bending phenomenon at the die exit during extrusion can be abtained by the two punches moving in the different velocity. And it is possible to design extrusion dies and to control the curvature of product through the simulation of extru-bending process by analysis

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.227-230
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• 2009

The aim of this study was to improve extrudability limit, eliminate welding line and obtain optimum thixoextrusion conditions for manufacturing tubes of 7075 Al wrought alloy. By thixoextrusion, it was possible to improve deformability, control isotropy with extrusion direction, eliminate welding line (seamless) and save cost due to low energy consumption compared with conventional extrusion processes. The welded part was not observed at the welding line area. The grains of thixoextruded tube were homogeneously distributed and equiaxed grains were observed. Therefore, thixoextrusion is the most effective variable for the control of the magnitude of the welding line.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.247-250
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• 2005

The need for improved fuel efficiency, weight reduction has motivated the automotive industry to focus on aluminum alloys as a replacement for steel-based alloy. To cope with the needs for high structural rigidity with low weight, it is forecasted that substantial amount of cast components will be replaced by tubular parts which are mainly manufactured by the extruded aluminum tubes. The extrusion process is utilized to produce tubes and hollow sections. Because there is no weld seam, the circumferential mechanical properties may be uniform and advantageous for hydroforming. However the possibility of the occurrence of a surface defect is very high, especially due to the temperature increase from forming at high pressure when it comes out of the bearing and the roughness of the bearing, which cause the surface defects such as the dies line and pick-up. And when forming a extruded aluminum tube, the free surface of the tube becomes rough with increasing plastic strain. This is well known as orange peel phenomena and has a great effect not only on the surface quality of a product but also on the forming limit. In an attempt to increase the forming limit of the tubular specimen, in the present paper, surface asperities generated during the hydroforming process are polished to eliminate the weak positions of the tube which lead to a localized necking. It is shown that the forming limit of the tube can be considerably improved by simple method of polishing the surface roughness during hydroforming. And also the extent of the crack propagation caused by dies lines generated during the extrusion process is evaluated according to the deformed shape of the tube.