• Journal of the Korean Society for Precision Engineering
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• v.27 no.5
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• pp.63-68
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• 2010

The use of aluminum alloy parts in the automotive industry has been increasing recently due to its low weight compared with steel to improve fuel efficiency. Companies in the auto parts' manufacturing sector are expected to meet the government's strict environmental regulations. In this study, manufacturing process of aluminum alloy bolt has been designed from forming to heat treatment. Bolt forming process is composed of cold forging for body and rolling for thread. In this study only cold forging process is considered by employing the finite element method. In the cold forging process, preform shape was designed and damage value was considered for die design. Two steps of forging process has been developed by the simulation and a prototype was manugactured accordingly. As a final process, solution heat treatment and aging process was employed. A final prototype was found to meet the required specifications of tensile strength and dimension.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.7
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• pp.4057-4064
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• 2014

In this paper, attempts were made to design a preform for a final punch inexpensively using the proposed approximate optimization method or metamodel-based simulation optimization. The design objective of this work is to achieve a uniform distribution of effective strains, the angle dimension of the preformed punch is chosen as a design variable, and maximum underfill ratio is used as a constraint. For this optimization, a computer simulation of a practical punch forging process is run using DEFORM software, in which a preformed punch(workpiece), a master punch(upper die), and a bottom die are dealt with. A validation method is introduced to determine if the simulation results match the actual forging process. In addition, this work presents the detailed design optimization procedure consisting of (i) generation of an initial metamodel, (ii) metamodel optimization, (iii) validation of metamodel-predicted optimum, and (iv) metamodel improvement.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.47-49
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• 2008

The brake pipe is important part in automobile. The brake pipe have to prevent crack, fracture and defects for braking in safety. Especially, shape of ends of pipe has influence on ability of brake. Based on the procedure of process design, in this paper, the forming operation is designed by finite element method. Design variable and response value was selected shape of die and damage factor. To improve die that performed FEM and compared results of two types of die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.139-142
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• 2007

This study focuses on the manufacturing process of a magnesium alloy impeller used for the fuel cell car using the hot forging technology. The impeller has the very complicated shape with sharply curved blade and thus generally produced by mechanical machining or casting process. However, since these technologies give the high manufacturing cost or poor mechanical properties, the forging technology is required to make the high-quality impeller with the lower manufacturing cost. In order for production of the impeller by forging technology, the parametric studies using finite element analyses were carried out to find the optimal perform shape of impeller made of magnesium alloy AZ 31 and finally die design was proposed based on the simulation results.

• Journal of the Korean Society of Industry Convergence
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• v.20 no.2
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• pp.141-148
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• 2017

A process comprising a hot extrusion process and a warm forging process was designed to form a T-shaped aluminum structural component with a high degree of difficulty by the plastic forming method. A circular cylindrical part was extruded with a hot extrusion process, and then an embossing part was formed with a warm forging process. The formability and the maximum load required for forming were then determined using a forming analysis program. The hot extrusion process was executed at $450^{\circ}C$ under the extrusion speed at 6 mm/s, while the warm forging process was executed at $260^{\circ}C$ under the forging speed at 150 mm/s. For both the processes, a condition by which friction would not be generated between the mold and the material was implemented. The analysis results showed that the load required for hot extrusion was 1,019 tons, while the load required for the warm forging was 534 tons. The T-shaped part was manufactured by using a 1,600 tons capacity press. The graphite lubricant was coated on the mold as well as the material. A forming experiment was performed under the same condition with the analysis condition. The measured values from the load cell were 1,210 tons in the hot extrusion process and 600 tons in the warm forging process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.94-97
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• 1999

The study has been performed for the relation between die and product in closed die upsetting by the experiment. the strain of die has been given by the simple experiment using the strain gauge located at the outer surface of die and the deformation history of die and product has been given by the experiment and Lame's formula. the product with accurate dimension and shape can be obtained by analysing elastic deformation of die during upsetting process. The deformation of die during metal forming process has been given by the experiment and lame's formula. The product with accurate dimension and shape can be obtained by analysing elastic deformation of die during upsetting process. The deformation of die during metal forming process has been usually predicted by the experience of industrial engineers of finite element analysis. But it is difficult to predict the dimension of product at unloading and ejected states. The study has given useful result for the deformation history of die and product through the experiment and Lame's formula at closed die upsetting and can be applied in the die design for product with accurate dimension.

• Transactions of Materials Processing
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• v.3 no.1
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• pp.110-119
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• 1994

In this paper, a new forming process of large-size forgings of converged nozzle-shape is developed by the experimental study using the incremental forging method and combined forming method. The development of the forming process is focused on the manufacturing of large-size forgings by the press with medium load capacity. Various related processes are proposed and modelling experiments using plasticine are carried out. Thus, the incremental forging method for expanding is recommanded from the study of formability and forming load, etc. The selected process is then subjected to modelling experiments of lead and the design parameters such as preform for final process, die-width of the upper die and reduction amount of each stroke are determined. In order to verify the effectiveness of the selected process, 1/7 scale prototype experiment of the real material is carried out. Forgings of converged nozzle shape can be produced by the developed process within the limit loads and with the simple tools.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.2
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• pp.594-603
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• 1996

It has been known that the life time of cold forging dies is shorten by the cracks and wear produced during the operation. Thus it is required to mak the same new one too often, At this time of making new ont the cutting work and electical discharge machining were mormally used. But the precision of product is declined in every times of making the mew dies due to the diffefence in dimensional accuracy arised from the electical discharge machining. Especially it can't meet the delivery date because the production was delayed for making another die. Furthemore it has the problem of increasing the production cost. Therfore inthis study we tried to solve these problems using the hobbing method instead of electical discharge machining.

• Transactions of the Korean Society of Automotive Engineers
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• v.14 no.3
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• pp.44-50
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• 2006

The mono steel forged piston was improved a mechanical strength of an aluminum piston and reduced the weight of a articulated piston. The mono steel forged piston was composed of forged crown part and forged skirt part and was completed by friction welding process of two forged parts. Forging process analysis and friction welding analysis was done by finite element simulation using numerical package DEFORM. The preform shape and the initial billet dimension were decided by maximum stress of the die, amount of the flash and filling of die. The upset length of friction welding variable was decided by the shape of the flash that was created by friction welding analysis. Through this research, we developed a forging process of the mono steel forged piston, and decided the design variables of friction welding.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.4
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• pp.29-38
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• 2003

This paper deals with an automated computer-aided process planning and die design system with which designer can determine operation sequences even after only a little experience in process planning and die design of multi former-bolt products by multi-stage former working. The approach is based on knowledge-based rules, and a process knowledge base consisting of design rules is built. Knowledge fur the system is formulated from plasticity theories, empirical results and the empirical knowledge of field experts. Programs for the system have been written in AutoLISP for AutoCAD with a personal computer. 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 die design module considers several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. It 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 and the level of the required forming loads by controlling the forming ratios. The system uses 2D geometry recognition and is integrated with the technology of process planning, die design, and CAE analysis. The standardization of die parts for multi former-bolt products requiring a cold forging process is described. The system developed makes it possible to design and manufacture multi former-bolt products more efficiently.