• Title/Summary/Keyword: Metal die

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Design of Porthole Extrusion Die for Improving the Welding Pressure in Welding Chamber by using the FE Analysis and Taguchi Method (유한요소해석 및 다구찌법을 이용한 접합실 내 접합압력 향상을 위한 포트홀 압출 금형 설계)

  • Lee, S.Y.;Lee, I.K.;Jeong, M.S.;Ko, D.C.;Lee, S.K.
    • Transactions of Materials Processing
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    • v.28 no.6
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    • pp.347-353
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    • 2019
  • The porthole extrusion process is a classic metal forming process to produce complex cross-section shaped aluminum profile. It is very difficult to design porthole die and extrusion process because of the complex shape of extrusion die and internal metal flow. The main variables in this process are ram speed, initial billet and tool temperature, and die shape. In general, the metal flow of porthole extrusion process can be divided into two steps. During the first step, the billet is divided into several parts in the porthole die bridge. During the second step, the divided billets are welded in the welding chamber. In the welding chamber, the level of welding pressure is very important for the quality of the final product. The purpose of this study is to increase the welding pressure in the welding chamber by using a two stage welding chamber. The porthole extrusion die was designed by using the Taguchi method with orthogonal array. The effectiveness of the optimized porthole die was verified by using the finite element analysis.

Development of The Center Carrier Type Progressive Die for Thick Sheet Metal

  • Sim, Sung-Bo;Lee, Sung-Taeg;Song, Young-Seok;Baek, Dong-Hak
    • Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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    • 2001.05a
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    • pp.295-300
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    • 2001
  • The progressive die performs a series of fundamental sheet metal working, particularly this study regards to develop the center carrier feeding type die for thick sheet metal(SS41, 2.5mm) production that is a specific division. In order to prevent defect on the production, the analysis of production part, optimum design of strip process layout, die design and die making and tryout etc. are necessary. In this study, we designed and predicted a progressive die of multi stages by wide collected data base and computer aided method.

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Modeling the Behavior of Trapped Air in Die Cavity During Sheet Metal Forming (판재성형 해석시 금형내의 공기거동 모델링)

  • Choi, Kwang-Yong;Kim, Heon-Young
    • Transactions of Materials Processing
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    • v.20 no.5
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    • pp.377-386
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    • 2011
  • During stamping processes, the air trapped between sheet metal and the die cavity can be highly compressed and ultimately reduce the shape accuracy of formed panels. To prevent this problem, vent holes and passages are sometimes drilled into the based on expert experience and know-how. CAE can be also used for analyzing the air behavior in die cavity during stamping process, incorporating both elasto-plastic behavior of sheet metal and the fluid dynamic behavior of air. This study presents sheet metal forming simulation combined simultaneously with simulation of air behavior in the die cavity. There are three approaches in modeling of air behavior. One is a simple assumption of the bulk modulus having a constant pressure depending on volume change. The next is the use of the ideal gas law having uniform pressure and temperature in air domain. The third is FPM (Finite point method) having non-uniform pressure in air domain. This approach enables direct coupling of mechanical behavior of solid sheet metal and the fluid behavior of air in sheet metal forming simulation, and its result provides the first-hand idea for the location, size and number of the vent holes. In this study, commercial software, PAM-$STAMP^{TM}$ and PAM-$SAFE^{TM}$, were used.

A Study on the Development of Multi-pilotting-type Progressive Die for U-bending Part Process

  • Sim, Sung-Bo;Lee, Sung-Taeg;Jang, Chan-Ho
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.2 no.2
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    • pp.45-51
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    • 2003
  • The multi-piloting type progressive die for U-bending sheet metal production part is a very specific division. This study reveals the sheet metal forming process with multi-forming die by center carrier type feeding system. Through the FEM simulation by DEFORM, it was accepted to u-bending process as the first performance to design of strip process layout. The next process of die development was studied according to sequence of die development, i.e die structure, machining condition for die making, die materials, heat treatment of partially die components, know-how and so on. The feature of this study is the die development of scrapless progressive die of multi-stage through the modeling on the I-DEAS program, components drawing on the Auto-LISP, CAD/CAM application, ordinary machine tool operating and revision by tryout.

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A STUDY ON THE ACCURACY OF DENTAL CAST AND DIE MATERIALS USING PHOTO-SCANNING (사진 주사(走査)를 이용한 치과용 모형재의 정확도에 관한 연구)

  • Yang, Seong-Wook;Lim, Ju-Hwan;Cho, In-Ho
    • The Journal of Korean Academy of Prosthodontics
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    • v.34 no.2
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    • pp.320-334
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    • 1996
  • Dental cast and die materials are essential material using in almost dental prsthodontic procedure and it's most important requirement is accuracy for reqorducing the oral anatomical structures. In this study, 5 abutments A, B, C, D, E were fabricated on the metal master model to simulate the arch form and specimens were poured with 4 cast materials. Inter-abutment distances, A-B, A-C, A-D, A-E, B-C, B-D were calculated using the photo-scanning and the deviations from the metal master model were also evaluated. The results were as follows; 1. The distance between A-B, A-C, A-D, A-E, B-C, B-D of the abutments A, B, C, D, E of each cast material was calculated. And after comparing the deviations between the metal master model. $Fujirock^{(R)}$ showed the lowest value with $0.20{\pm}0.22mm$, and the deviation increased in the order of $Suprastone^{(R)}$, Epoxy $Die^{(R)}$, Die $Keen^{(R)}$. There was significant difference between $Fujirock^{(R)}$ and Epoxy $Die^{(R)}$, Die $Keen^{(R)}$. 2. In each calculation area, the difference in measurements between cast material and metal master model showed singificant difference between A-B and Cross arch measure-ments of A-D, B-D, A-E(p<0.05). 3. The difference in measurements between cast material and metal master model in the A-B area showed $Fujirock^{(R)}$ to be the lowest with $0.05{\pm}0.04$mm and increased in the order of Die $Keen^{(R)}$, $Suprastone^{(R)}$, Epoxy $Dies^{(R)}$. There was significant difference between $Fujirock^{(R)}$ and $Suprastone^{(R)}$, Epoxy $Die^{(R)}$ (p<0.05). 4. The difference in measurements between cast material and metal master model in the B-C area showed $Fujirock^{(R)}$ to bo the lowest with $0.17{\pm}0.11$mm and increased in the order of $Suprastone^{(R)}$, Die $Keen^{(R)}$, Epoxy $Dies^{(R)}$. There was significant difference between $Fujirock^{(R)}$ and Die $Keen^{(R)}$, Epoxy $Die^{(R)}$(p<0.05). 5. The difference in measurements between cast material and metal master model in the B-D area showed $Fujirock^{(R)}$ to bo the lowest with $0.13{\pm}0.07$mm, Epoxy $Dies^{(R)}$and increased in the order of $Suprastone^{(R)}$, Die $Keen^{(R)}$. There was significant difference between $Fuji-rock^{(R)}$ and Die Keen(p<0.05). 6. In this experiment, Epoxy $Dies^{(R)}$ showed mean contraction in every calculation area. And when reconstruction cross arch restorations it is thought that distortion should be considered in every cast material.

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Densification Behavior of Metal Powder Under Warm Isostatic Pressing with a Metal Mold (금속 몰드를 이용한 금속 분말의 온간 등가압 성형)

  • Park, Jung-Goo;Kim, Ki-Tae
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.28 no.6
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    • pp.838-847
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    • 2004
  • The effect of a metal mold on densification behavior of stainless steel 316L powder was investigated under warm isostatic pressing with a metal mold. We use lead as a metal mold and obtain experimental data of metal mold properties. To simulate densification behavior of metal powder, elastoplastic constitutive equation proposed by Shima and Oyane was implemented into a finite element program (ABAQUS) under warm die pressing and warm isostatic pressing with a metal mold. Finite element results were compared with experimental data for densification and deformation of metal powder under warm isostatic pressing and warm die pressing.

Densification behavior of metal powder under warm isostaic pessing with metal mold (금속 몰드를 이용한 금속 분말의 온간 등가압 성형)

  • Park, Jung-Goo;Kim, Ki-Tae
    • Proceedings of the KSME Conference
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    • 2003.11a
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    • pp.1352-1357
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    • 2003
  • The effect of the metal mold on densification behavior of stainless steel 316L powder was investigated under warm isostatic pressing with metal mold. We use lead as metal mold and obtain experimental data of metal mold property. To simulate densification of metal powder, the elastoplastic constitutive equation proposed by Shima and Oyane was implemented into a finite element program (ABAQUS) under warm die pressing and warm isostatic pressing with metal mold. Finite element results were compared with experimental data for densification and deformation of metal powder under warm isostatic pressing and warm die pressing.

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A Study on the Relation between Bead Shape and Welding Parameters of GMA Welding far Die Remodeling (금형수정 GMA 용접에 있어서 용접조건과 비드 형상과의 상관관계에 관한 연구)

  • 김지태;나석주;김덕환;서만석
    • Journal of Welding and Joining
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    • v.20 no.3
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    • pp.60-66
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    • 2002
  • Almost every die fur automobiles must be corrected or remodeled for minor geometrical changes or for better hardness characteristics by arc welding process. Although many other kinds of arc welding processes have been automated with robots, this molten metal deposition process for die remodeling still depend entirely on experienced welders. In this study, the database for bead shapes with respect to welding parameters are constructed by experiments to automate the molten metal deposition by arc welding process. And the changes of welding parameters for inclined base metal are studied to consider the effect of die geometries fur the welding process.

Influence of die design variables on the sheared surface in cut-off process of sandwich sheet metal (샌드위치 강판의 전단가공에 있어서 전단면에 미치는 금형 설계 변수의 영향)

  • Kim J. Y.;Choi J. S.;Kim J. H.;Chung W. J.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2004.05a
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    • pp.57-61
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    • 2004
  • in order to improve the quality of the sheared surface in cutting of sandwich sheet metals the cut-off operation is mainly investigated which is the typical shearing process in sheet metal forming technology. For experiments the cut-off die is made which can be easily adjusted by die design variables such as blankholding force, pad force, and clearance. The sheet metals chose as specimen are clad304(STS304-Al1050-STS304) and anti-vibration sheet metal. The shearing process is visualized by the computer vision system installed in front of the cut-off die and the sheared surface before and after cut-off operation is measured and quantitatively compared with the help of the optical microscope. From test results the good sheared surface was shown when the clearance gets small with large blankholding force.

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A Study on the Progressive Die Development of Sheet Metal Forming Part (박판 포밍제품의 프로그레시브 금형개발에 관한 연구)

  • Sim, Sung-Bo;Lee, Sung-Taeg
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.3 no.4
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    • pp.43-49
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    • 2004
  • The production parts have required multiple processes such as drawing, piercing, blanking and notching etc. are performed with a high production rates in progressive die. In order to prevent the defects of process result, the optimization of strip process layout design, die design, die making, and tryout etc. are needed. According to these factors of die development process, it has been required that the theory and practice of metal working process and its phenomena, die structure, machining conditions for die making, die materials, heat treatment of die components, processing know-how and so on. In this study, we designed and analyzed die components through the carrying out of upper relevant matters also simulated the strip process layout of multiple stage drawing by DEFORM. Especially the result of tryout and its analysis became to the feature of this study with a system of PDDC(Progressive Die design by computer).

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