• 제목/요약/키워드: Forging mold

검색결과 44건 처리시간 0.023초

사각형 판재성형 시 벽두께 증육을 위한 금형 및 공정 설계 (Process and Die Design of Square Cup Drawing for Wall Thickening)

  • 김진호;홍석무
    • 한국산학기술학회논문지
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    • 제16권9호
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    • pp.5789-5794
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    • 2015
  • 최근 스마트 폰, 모바일 PC 제품의 외관에 필요한 가벼운 금속제품으로 제조를 하기 위하여 알루미늄 압출 공정과 CNC 가공기법을 적용한 생산방식이 널리 사용되고 있다. 하지만, 알루미늄 압출법은 외관 디자인의 제약이 있으며, 특히 CNC 가공 프로세스가 상대적으로 높은 생산 비용 및 낮은 생산성으로 생산단가가 많이 높은 단점이 있다. 본 연구에서, 새로운 처리 방법을 순서 재료비를 대폭 감소시키고, 제조 속도를 향상시키기 위해 판재성형과 부피성형의 두가지 공정을 섞어 새로운 판단조 공정을 개발하였다. 새로운 판단조 공법(hybrid plate forging)이란 우선 일반적인 딥드로잉으로 중간 모양을 만든 후 원하는 벽 부위만 증육을 하는 방법을 의미한다. 이러한 판단조 공법을 활용하여 재료의 낭비와 제조 시간을 최소화하는 것이 가능하게 된다. 본 연구에서는 상용 유한 요소 프로그램 AFDEX-2D를 통해 판단조공정을 설계하였고 최적의 사용 가능한 소재의 두께와 초기 폭을 설계하였다. 최종적으로 실제 노트북 케이스 금형을 제작하여 제안한 방법의 타당성을 검증하였다.

비선형 열전달 계수를 사용한 알루미늄 6082 빌렛의 열간 압축 공정 해석 (Analysis of Hot Compression Process of Aluminum 6082 Billet using Nonlinear Heat Transfer Coefficient)

  • 전효원;서창희;권태하;박춘달;전진호;최현열;강경필
    • 소성∙가공
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    • 제28권1호
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    • pp.5-14
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    • 2019
  • In order to reduce the weight of automobile parts, automobile parts using aluminum alloy are being developed. Aluminum alloy for automobile parts is mainly made of Al6xxx (Al-Mg-Si) type alloy, which is excellent in hot forming property, and it can increase mechanical properties by the use of heat treatment. In this study, hot forming was performed using Al6082. Before the hot forming, the forming analysis was performed using the DEFORM-3D finite element analysis program in this case. For the forming analysis, the heat transfer coefficient was derived from the experiment, and the forming analysis was performed by applying it. At the forging analysis, the temperature of Al6082 material was set to 813K and that of the mold was set to room temperature. After the forging analysis, the experiment was performed, and the forging analysis and the experimental results were compared.

OPTIMAL PREFORM DESGIN BY TRACING THE MATERIAL FLOW : APPLICATION TO PISTON FORGING

  • Hong J.T.;Lee S.R.;Park C.H.;Yang D.Y.;Chung W.J.;Park Y.B.;Kim Y.H.
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 2003년도 The 8th Asian Symposium on Precision Forging ASPF
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    • pp.143-146
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    • 2003
  • In this paper, a new preform design method is proposed to eliminate the excessive flash in metal forging process. After carrying out finite element simulation of the process with an initial billet, backward particle tracing is performed from the outlet of the flash. Then, the region which belongs to the flash is easily found .. The process is analyzed again with the redesigned billet which is removed that region the above mentioned region. The optimal preform shape which minimizes the amount of flash without changing the forgibility can be obtained in several iterations.

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단조 금형 SCM435 고장력 볼트의 파손 해석 (Failure Analysis on SCM435 High Strength Bolt of Forging Die)

  • 윤서현;김민헌;남기우
    • 한국산업융합학회 논문집
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    • 제22권6호
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    • pp.649-655
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    • 2019
  • Fracture behaviors of SCM435 high strength bolt have been studied including macroscopic and microscopic fracture observation, Energy Dispersive X-ray Spectroscopy, Vickers hardness test and applied stress evaluation. cracks (ratchet marks) were generated by the repetitive loads acting on the bolts, initial stress of bolt and the stress concentration. The applied stress was found to be slightly higher than the fatigue limit of the material. The initial stress of bolt must be removed, and the mold temperature during the process must be maintained by room temperature. Bolts are recommended to be peened to improve fatigue limit.

초내열합금 링제품의 형상링 압연 제조 기술 (Profile Ring Rolling Manufacturing Technology of Alloy 718)

  • 김태옥;김국주;김남용;이진모;염종택
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 2009년도 추계학술대회 논문집
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    • pp.425-428
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    • 2009
  • Aerospace engine application needs to stand high temperature and pressure. Because of its mechanical properties such as high strength at high temperature, Alloy 718 is used aerospace engine application about 80%. But alloy 718's mechanical properties cause some problem to manufacturing profile ring like damage of material and mold. In this study, alloy 718's mechanical properties investigated for knowing its formability and using FE-Simulation for designing profile ring roll process and mold shape. Profile ring rolling processing is designed with "Initial material$\rightarrow$Blank$\rightarrow$Linear Ring$\rightarrow$Profilering". Blank's heating temperature is setting $1100^{\circ}C$ for manufacturing a trial profile ring on the basis of FE-Simulation. As a result of manufacturing alloy 718 profile ring, it is possible to make near target profile shape ring with all of the processing condition which gives in this study.

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국내 파인블랭킹 산업 현황과 기술 개발 (Korean fine blanking industries and technology development)

  • 김종덕
    • Design & Manufacturing
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    • 제9권1호
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    • pp.5-8
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    • 2015
  • The company Daewoo Precision Industries imported fine blanking press of 40 tons from Switzerland with fine blanking tool in order to produce the fuse part of bomb in 1978 at first in Korea. About 1985 the first fine blanking tool for producing the door lock parts was manufactured in the company Gold Star (now LG). And then this technology was grown up with the growth of automobile industries in Korea. Now 31 companies are closely related to the fine blanking technology and there are total 146 fine blanking presses in Korea. The developments of fine blanking technology in industries have been oriented to the production of precise fine blanking parts, the reduction of die roll height on fine blanking parts, the production of complex fine blanking parts with progressive fine blanking tool including forming and forging technology, the production of high-strength steel fine blanking parts and so on. Some R&D activities in KITECH were introduced.

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유한요소법을 이용한 SCM435 Bolt의 성형 공정에 관한 해석 및 공정 개선 방안 (Plan on the Analysis and Improvement of the Molding process of SCM435 bolt by use of the Finite Element Method)

  • 안교철;최취경
    • 한국산학기술학회논문지
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    • 제13권11호
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    • pp.4950-4955
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    • 2012
  • 볼트의 제작 공정은 연속적인 단조 작업에 의해서 완성되는데 각 공정의 기술적, 경제적인 성공은 적절한 공정설계와 각 작업에 필요한 금형 설계에서 좌우된다. 본 연구에서는 다단 공정에 의해서 이루어지는 SCM435 볼트의 성형과정 중에서 1, 2단계의 성형을 유한요소법을 이용하여 해석하여 합리적인 공정이 이루어지도록 개선 방향을 제시하고자 하며 유한요소법을 이용하여 해석한 1, 2단계의 공정은 축대칭이 성립되므로 소재의 변형 형상이 공정에서 기대했던 치수를 만족할 수 있었으며 소재에 형성된 단류선이 전 공정을 통하여 부드럽게 연속적으로 형성됨을 알 수 있었으므로 소재의 성형 뿐 아니라 내부의 결함도 없을 것으로 예상되었다.

CAE를 활용한 모바일 디바이스 부품의 블랭킹 공정 시 클리어런스에 따른 치수정밀도 분석 (Analysis of dimension precision of mobile device components according to the clearance in blanking process using CAE)

  • 김태민;최두선;한봉석;한유진;고강호;박정래;박규백;이정우;임동욱
    • Design & Manufacturing
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    • 제14권2호
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    • pp.7-13
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    • 2020
  • For one decades, mobile devices components were made with plastic material, but environmental problems have recently replaced them with metal materials such as aluminum. Generally, aluminum components are mostly produced through cutting, but this process has limitations such as productivity and chip recycling. For this reason, many researches are conducted to improve productivity by replacing with the forging press process for manufacturing mobile device components. After forging process, the flash is remained and it is necessary to eliminate the flash from the final shape of components. In this paper, one-sided clearance for blanking aluminum material wes selected for parameter affected to the dimensional precision. Because the clearance is the most important parameter in blanking process. Deriving the clearance of blanking process for high dimensional precision, five level of one-sided clearance is selected and CAE is used to analyze the dimensional precision for each case.

모바일 기기용 초소형 나사의 냉간 단조 공정 설계 (Design of Cold Forging Process of Micro Screw for Mobile Devices)

  • 최두순
    • 한국산학기술학회논문지
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    • 제16권6호
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    • pp.3692-3697
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    • 2015
  • 나사는 나선형의 홈으로 구성된 체결용 기계요소이다. 최근의 모바일 기기의 소형화 추세로 인하여 나사의 소형화 및 경량화 요구도 크게 증가하고 있는 실정이다. 우수한 기계적 성질과 높은 정밀도의 나사를 생산하기 위해서는 금형 및 공정설계가 성공적으로 수행되어야 한다. 본 연구에서는 유한요소해석을 통하여 초소형 나사의 머리부 냉간 단조 성형에 대한 공정설계를 수행하였다. 특히, 금형의 형상과 마찰력이 성형에 미치는 영향을 분석하기 위하여 실험계획법을 적용하였고, 그 결과 마찰력이 성형 시 발생하는 접힘 결함의 지배적인 요인임을 밝혀내었다. 이러한 결과로부터 금형 형상을 개선하였고, 개선된 금형으로 단조 실험을 수행하였고, 실험 결과로부터 접힘 결함 불량이 해소된 것을 확인하였다.

냉간단조용 WC-Co 금형의 수명에 미치는 WC 분말의 미세구조 및 Co 부피 분율의 분석 (Analysis in Microstructures and Co Volume of WC Powder According to the Lifespan of WC-Co Molds for Cold Forging)

  • 오정석;박지니;이상엽;정중희;최정묵;박준식
    • 열처리공학회지
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    • 제36권5호
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    • pp.270-276
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    • 2023
  • In this study, we analyzed two types of cold forging dies commonly used for manufacturing general nuts and screws to investigate the differences in WC powder according to the lifespan. For both Type I and Type II dies, it was observed that as the lifespan of the molds increases, the area fraction of Co becomes larger and the size of the powder becomes smaller. Moreover, there is a trend where the strength also increases as the lifespan gets longer. Actually, the hardness value of the sample with the longest lifespan is ~ 131 HV higher than the specimen of the shortest lifespan, It is noted that the reduction in toughness of the WC-Co mold is caused by insufficient Co and the decrease in contact surface area of WC-Co results in a reduced bonding surface area. The lifespan of cold-working WC molds increases when the W content and the volume fraction of WC are high, and the size of the WC powder is small. The results can significantly enhance producing high-quality molds with an extended lifespan using WC powder for cold forging.