• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.281-284
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• 2009

Flexible forming process for sheet metal using reconfigurable die is introduced based on numerical simulation. Numerical simulation of sheet metal forming process is carried out by using flexible dies model instead of conventional matched die set. Elastic cushion which has high resilience behavior from excessive deformation are inserted between forming punches and blank material for smoothing the forming surface which has discrete due to characteristics of the flexile die. As an elastic cushion, urethane pads are utilized using hyperelastic material model in the simulation. Formability in view of surface defect such as onset of dimple is compared with regard to various punch sizes. Consequently, it is confirmed that the flexible forming process for sheet material has appropriate capability and feasibility for manufacturing of smoothly curved surface instead of conventional die forming process.

• Transactions of Materials Processing
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• v.16 no.7
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• pp.538-548
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• 2007

In this paper, a novel approach which enables rapid die surface modification for sheet metal forming process is proposed. In this method an implicit surface which interpolates a given set of control points and displacement constraints is generated to compute the displacements at arbitrary points located on die surface. The proposed method does not depend on the underlying surface representation type and is affected neither by its complexity nor by its quality. In addition, the domain decomposition method is introduced in order to treat large surface model. The global domain of interest is divided into smaller domains where the problem can be solved locally. And then the local solutions are combined together to obtain a global solution. In order to verify the validity and effectiveness of the proposed method, various surface modifications are carried out fur three kinds of die surface model including polygonal surface composed of triangular and rectangular meshes, polynomial surface and NURBS surface.

• Design & Manufacturing
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• v.8 no.1
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• pp.27-30
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• 2014

Alloy tool steel such as SKD11 and SKD61 or high speed tool like SKH51 are used as materials for semiconductor dies. Cavities, curl blocks, pot blocks and housings are made from those materials. To make those parts from alloy tool steel or high speed tool, one utilizes discharge machining, and mechanical machining including machining center, milling, drilling, forming grinding and others. In the process of cutting machining and polishing, the die materials become unsuitable for machining owing to bubbles and foreign substances in them, which hinders production process. Therefore, this study focuses on die material selection criteria, and on analysis and comparison of material characteristics to help companies to solve their problems, make die manufacture less burdensome and extend die life.

• Transactions of Materials Processing
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• v.12 no.3
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• pp.214-220
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• 2003

In the case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. There have been few studies about condenser tube extruded by porthole die. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to variation of chamber length in porthole die. The welding chamber height in condenser tube was calculated by using finite element method. Forming analysis results for condenser tube would provide useful information for the optimal design of porthole die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.06a
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• pp.135-147
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• 1997

The production of light metal parts using aluminum is mainly performed by die casting and squeeze casting, which directly fabricate the required shape from the liquid state. However, die casting is subject to defects such as shrinkage porosity and air trapped when molten metal enters the cavity, whilst squeeze casting also has defects due to turbulent flow in the die cavity. Both diecasting and sqeeze casting have inhomogeneous mechanical property in terms of dendritic structure during solidification. Active research has been carried out on semi-solid processing, rather than on conventional process methods such as die casting, which involve various problems. Therefore in this paper, to introduce the fundamental technology for d e design, in die casting and forging process with semi-solid materials, relationship between stress and strain of semi-solid materials, and for producing parts die design has been proposed as parameters of globulization of the microstructure and gate shape. The prevention of various defects to produce sound parts are also introduced.

• Transactions of Materials Processing
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• v.9 no.4
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• pp.413-420
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• 2000

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of front housing part of aircon compressor, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the filling and solidification stages for the sound casting products. Two cases of casting design that have different types of gating system are considered in the analysis. The potential sites where the casting defects may occur is examined by computer simulation and an improved design process is proposed. Also the effect of partial squeeze on the quality of casting products is considered and the optimal time lag after filling process is determined. For the die-stability, the effect of operational parameters such as die temperature, heat cycle and spot cooling on the die life has also been analyzed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.358-363
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• 2001

In sheet metal forming, material cost and die process number are very important manufacturing process for an economic die-making. In this report on implemention of a computer aided sheet-metal nesting program for nesting of irregular shaped blank on ae coil strip of limit width. The result of the computing in the nesting program reduced material cost and die process number.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.2
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• pp.276-280
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• 2008

The design technology to be developed in this study is technology related to the metal panel comer processing method of very high value-added, interior and exterior cladding material, in the architecture. This study is aimed at designing a Bending Die System that enables metal panel comer processing for the first time in Korea, by improving corrosion resistance (durability), weather resistance and elegances (design) for the connecting part of right angle cornering, where most serious problems occur in using metal steel plates of 2.5mm or thicker. This is used as a kind of metal ball and as architectural interior and exterior cladding material.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.6
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• pp.1518-1522
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• 2008

The design technology to be developed in this study is technology related to the metal panel corner processing method of very high value-added, interior and exterior cladding material, in the architecture. This study is aimed at designing a Bending Die System that enables metal panel corner processing for the first time in Korea, by improving corrosion resistance (durability), weather resistance and elegances (design) for the connecting part of right angle cornering, where most serious problems occur in using metal steel plates of 2.5mm or thicker. This is used as a kind of metal ball and as architectural interior and exterior cladding material.

• Design & Manufacturing
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• v.7 no.1
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• pp.28-33
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• 2013

During the cold forming, due to high working pressure acting on the die surface, failure mechanics must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The mechanisms of wear are consisted of adhesion, abrasion, erosion and so on. Die wear affects the tolerances of formed parts, metal flow, and costs of process. The only way to control these failures is to develop a prediction method on die wear suitable in the design state in order to optimize the process. The wear system is used to analyse 'operating variables' and 'system structure'. In this study, with AISI D2, AISI 1020, AISI 304SS materials, a series of the wear experiments of pin-on-disk type to obtain the wear coefficients from Archard's wear model and the upsetting processes are carried out to observe the wear phenomenon during the cold forming process. The analysis of upsetting processes are performed by the rigid-plastic finite element method. The result of the analysis is used to investigate the die wear the processes, and the analysis simulated die wear profiles are compared with the experimental measured die wear profiles.