• Design & Manufacturing
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• 제10권2호
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• pp.24-28
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• 2016

In this study, relevant to impact extrusion process of the rectangular batter case for electric vehicles, numerical and experimental analyses were conducted to reduce the earring defects induced in the unevenness of metal flow. Since the earring is caused by the non-uniform metal flow induced in the friction and aspect ratio in the bottom section. As a way to reduce the earring, variable land die concept was applied. In order to analyze numerically the complex metal flow by using commercial finite element package, DEFORM 3D, impact extrusion process was simplified in upsetting mode at bottom section and extrusion mode at land section. The impact extrusion experiments were conducted to verify the assessment of process parameter for impact extrusion. As results, variable land die which has longer longitudinal section makes reduce earring defects. In addition, it was confirmed that the effect that slug shape like dog-bone also can reduce the earring. This study is expected to be able to present the useful design guidelines for manufacturing the battery case.

• 소성∙가공
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• 제24권5호
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• pp.323-331
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• 2015

Impact extrusion is an economical and productive process that can replace the multistage deep drawing process for producing deep rectangular cases. In the current work, a three-dimensional finite element analysis of the impact extrusion process of a commercial purity aluminum alloy (AA1070) was performed to predict loads, material flow, and deformed shapes using the Hansel-Spittel rheology law, which describes the flow stress at various temperatures and strain rates. The role of various process parameters such as friction, clearance between punch and die, aspect ratio and thickness of billet on the process and the shapes was analyzed.

• 소성∙가공
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• 제24권6호
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• pp.425-430
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• 2015

In the current paper, the effects of initial slug design on the earring of an Al rectangular battery case manufactured by impact extrusion were studied. During impact extrusion, non-uniform metal flow between the long and the short sides of the battery case leads to earring, which is subsequently trimmed. Process parameters such as friction, aspect ratio of the battery case, the die shape and the forming temperature tend to induce earring because they cause greater non-uniform metal flow. Large aspect ratio of the battery case and high friction between slug and die can greatly affect the earring of a rectangular battery case. To make a rectangular battery case without earring, it is necessary to control metal flow uniformly during impact extrusion. One of the ways to reduce the earring is to control the metal flow of slug at the initial upsetting stage. To analyze the effects of the initial slug design on earring, FE analysis was conducted using DEFORM 3D. Two types of initial slug designs were evaluated where volume was removed along either the width or thickness directions. The results show that the initial slug design can be effective in adjusting the uniformity of metal flow.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 춘계학술대회 논문집
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• pp.628-631
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• 2002

This paper has executed FE-analysis to review the feasibility for developing the process, which produces the narrow-cubic type cans, using the Backward Impact Extrusion process instead of using current process, multi-stage deep drawing. Proposes an analysis method by applying ALE(Arbitrary Lagrangian-Eulerian) description to non-axisymmetric extrusion. which is appreciated as one of good solution to mesh distortion in case of the large deformation plasticity process that has mass flux, and considers the factors which affects forming-loads related to punch velocity and fulid status of material.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2003년도 춘계학술대회 논문집
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• pp.1565-1568
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• 2003

The backward extrusion process is one of the commonly used metal forming processes. In this paper. a battery case which has the rectangular section, is analyzed using a 3D metal forming package(MSC.Superforge). This pacakge uses the finite volume analysis method. It is shown that the MSC.Superforge package using finite volume method provides result very close to those obtained from a finite element analysis package(MSC.Superform). However, the simulation time using the finite volume method was almost 10 % of the simulation time consumed by the other package using finite element method. Moreover, the finite volume method used in MSC.Superforge can eliminate the remeshing problems that make the simulating a metal forming process with severe deformation, such as the extrusion process, so difficult.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 추계학술대회 논문집
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• pp.641-645
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• 2002

In case of aluminum-cased battery, The ratio of height and base of square is generally above the ten times, square-shaped and problem of non-axis symmetry. It is typical model to set up the analysis method of finite element. The reliable analysis of finite element method is suggested, which is used to investigate the possibility that multi-stage deep drawing and ironing used currently is replaced by backward impact extrusion favorable in the respect of cost production and productivity. The influence of parameter was analyzed and compared, which was considered to analyze the process of large deformation plasticity such as extrusion. Die and billet was made as the same shape of finite element model. The results of experiment show good forming without the rupture and wrinkles with the optimum velocity 100mm/sec obtained by analysis.

• 소성∙가공
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• 제32권6호
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• pp.344-351
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• 2023

The use of Zn-Al-Mg alloy coatings for enhancing the corrosion resistance of steel sheets is gaining prominence over traditional Zn coatings. There is a growing demand for the development of thermal spray wires made from Zn-Al-Mg alloys, as a replacement for the existing wires produced using Al and Zn. This is particularly crucial to secure corrosion resistance and durability in the damaged areas of coated steel sheets caused by deformation and welding. This study focuses on the casting and extrusion processes of Zn-2Al-1Mg alloy for the fabrication of such spray wires and analyzes the changes in microstructure during the extrusion process. The Zn-2Al-1Mg alloy, cast in molds, was subjected to a heat treatment at 250 ℃ for 3 hours prior to extrusion. The extrusion process was carried out by heating both the material and the mold up to 300 ℃. Microstructural analysis was conducted using FE-SEM and EDS to differentiate each phase. The mechanical properties of the cast specimen were evaluated through compression tests at temperatures ranging from 200 to 300 ℃, with strain rates of 0.1 to 5 sec^-1. Vickers hardness testing was utilized to assess the inhomogeneity of mechanical properties in the radial direction of the extruded material. Finite Element Analysis (FEA) was employed to understand the inhomogeneity in stress and strain distribution during extrusion, which aids in understanding the impact of heterogeneous deformation on the microstructure during the process.

• Elastomers and Composites
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• 제34권3호
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• pp.212-221
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• 1999

Mechanical properties of polypropylene filled with recycled rubber dusts obtained from the buffing process in sport shoe sole manufacture were investigated. The use of these dusts eliminates the need for the size reduction process which is usually employed in rubber recycling. Two different waxes, polypropylene wax and ethylene vinyl acetate wax, were used in the PP/rubber dust compound. Two different processes, extrusion and injection moulding, were used to study the influence of the blends on the properties. The waxes gave significant improvement in the shaping of the extrudate. It was found that the impact strength of the injection moulded samples were higher than the extruded samples and the virgin PP. The tensile properties (yield stress and modulus) were dependent on the amount of rubber dust addition. An increase in the rubber dust loading gave lower yield stress and modulus.

• 접착 및 계면
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• 제17권3호
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• pp.96-103
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• 2016

본 연구에서는 셀룰로스계 천연섬유인 대나무와 poly(lactic acid) (PLA)로 구성된 펠렛을 압출공정으로 제조하고, 여러 가지 함량의 대나무섬유/PLA 바이오복합재료를 사출공정을 통해 성형하였다. 바이오복합재료의 굴곡, 인장, 충격 특성 및 열변형온도에 미치는 대나무섬유의 수처리 영향을 조사하였다. 천연섬유의 열안정성, 바이오복합재료의 굴곡특성, 인장탄성률 및 충격특성은 섬유 함량은 물론 수처리 유 무에 의존한 반면, 열변형온도는 주로 수처리에 의해 영향을 받았다. 바이오복합재료의 기계적 특성과 충격특성의 증가는 이를 구성하고 있는 대나무섬유와 PLA 매트릭스 사이의 계면결합력이 대나무섬유의 수처리에 의해 향상되었기 때문이다. 연구결과는 친환경적이고 작업친화적인 물을 이용한 천연섬유의 전처리가 바이오복합재료의 성능을 향상시키는데 기여할 수 있다는 것을 제시하여 준다.

• Journal of the Korean Wood Science and Technology
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• 제47권1호
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• pp.51-65
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• 2019

A wood-plastic composite (WPC) paver block was manufactured using wood chips waste through an extrusion process, and it was intended to be used for paving in basic rest areas. The first stage in this study covered preliminary tests in terms of flexural strength and dimensional swelling to determine the optimal WPC compounding mix condition, by variation of the WPC ingredients. Next, three different paver blocks including the WPC block, a non-porous cement block, and a porous cement block were tested in terms of various material properties in the laboratory. Finally, two outdoor test sections of the proposed paver blocks were prepared to simulate a basic rest area. Test results indicated that the flexural strength of the WPC paver blocks was about 1.6 times greater than that of the tested cement paver blocks. The WPC block pavement was unaffected by water buoyance as well as volume expansion due to swelling. Results from the impact absorbance test and light falling weight deflectometer (LFWD) test clearly showed that the WPC block paving system marginally satisfied the comfortable and safe hardness range from the pedestrians' perspective, while the results demonstrated that it is structurally sound for application as a road paving block.