• Title/Summary/Keyword: Multi-Stage Automatic Cold Forging

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Rigid-Plastic Finite Element Analysis of Multi-Stage Automatic Cold Forging Processes by Combined Analyses of Two-Dimensional and Three-Dimensional Approaches (2차원 및 3차원 연계해석을 통한 다단 자동냉간단조 공정의 강소성 유한요소해석)

  • Lee, M.C.;Joun, M.S.
    • Transactions of Materials Processing
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    • v.17 no.3
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    • pp.155-160
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    • 2008
  • We analyzed a sequence of multi-stage automatic cold forging processes composed of four axisymmetric processes followed by a non-axisymmetric process using rigid-plastic finite element based forging simulators. The forging sequence selected for an example involves a piercing process and a heading process accompanying folding or overlapping, which all make it difficult to simulate the processes. To reduce computational time and to enhance the solution reliability, only the non-symmetric process was analyzed by the three-dimensional approach after the axisymmetric processes were analyzed by the two-dimensional approach. It has been emphsized that this capability is very helpful in simulating the multi-stage automatic forging processes which are next to axisymmetric or involve several axisymmetric processes.

Rigid-Plastic Finite Element Analysis of Multi-Stage Automatic Cold Forging Processes by Combined Analyses of Two-Dimension and Three-Dimensional Approaches (2차원 및 3차원 연계해석을 통한 다단 자동냉간단조 공정의 강소성 유한요소해석)

  • Lee, M.C.;Joun, M.S.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2007.10a
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    • pp.195-200
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    • 2007
  • We analyzed a sequence of multi-stage automatic cold forging processes composed of four axisymmetric processes followed by a non-axisymmetric process using rigid-plastic finite element based forging simulators. The forging sequence selected for an example involves a piercing process and a heading process accompanying folding or overlapping, which all make it difficult to simulate the processes. To reduce computational time and to enhance the solution reliability, only the non-symmetric process was analyzed by the three-dimensional approach after the axisymmetric processes were analyzed by the two-dimensional approach. It has been emphsized that this capability is very helpful in simulating the multi-stage automatic forging processes which are next to axisymmetric.

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Numerical and Experimental Study on Spring Back in Automatic Multi-Stage Precision Cold Forging Process of a Steering Yoke (조향장치용 요크 자동다단 정밀냉간단조 공정에서 발생하는 스프링백의 수치적 및 실험적 검증)

  • Kim, K.M.;Kim, M.C.;Hwang, T.M.;Chung, S.H.;Chung, W.J.;Joun, M.S.
    • Transactions of Materials Processing
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    • v.28 no.3
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    • pp.115-122
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    • 2019
  • In this paper, finite element analysis of an automatic five-stage precision cold forging process of a yoke, a steering part of a passenger's car, is conducted with emphasis on spring back analysis at the yoke-forming stage and its experimental verification is subsequently made. An elastoplastic finite element method with MINI-element technique employed for the analysis of the entire process is explained. There is emphasis that the thin film of material formed between the punch and die in the stage may result to some errors especially in elastoplastic finite element analysis of spring back due to frequent remeshing. The numerical robustness of the spring back analysis in regards to remeshing is hence shown first through investigation into its effect on the predicted spring back. Experimental measurement of displacement due to spring back is carried out for comparison with the predicted results, and they are in a qualitative agreement with each other.

Finite Element Analysis of Compound Forging Processes (복합단조 공정의 유한요소해석)

  • 전만수;문호근;이민철;서대윤
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1996.04a
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    • pp.546-550
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    • 1996
  • A fully automatic computer simulation technique of axisymmetric multi-stage compound forging processes was presented in this paper. A penalty rigid-viscoplastic finite element method was employed together with an improved looping method for automatically remeshing with quadrilateral finite-elements only. An application example of six-stage axisymmetric forging processes involving one cold and two hot forging processes, two piercing processes and a sizing process was given with emphasis on automatically tracing the metal flow lines through the whole simulation.

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Automatic Process Design System for Cold Forging of Fasteners with Various Head Geometries (다양한 머리 형상을 갖는 체결구의 냉간 단조 자동 공정 설계 시스템)

  • 김홍석;임용택
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1994.10a
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    • pp.141-148
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    • 1994
  • In order to improve the productivity of cold forging at low production cost, an integrated system's approach is necessary in handling the material preparation and the optimum process design, considering the forming machines, tooling, and operation including quality control. As the first step toward this approach, an expert system for multi-stage cold forging process design for fasteners with various head geometries is developed using Prolog language on IBM 486 PC. For effective representation of the complex part geometries, the system uses the multiple element input, and the forward inference scheme in determination of the initial billet size and intermediate forging steps. In order to determine intermediate steps, the basic empirical rules for extrusion, heading, and trimming were applied. The required forming loads and global strain distributions at each forging step were calculated and displayed on the PC monitor. The designed process sequence drawing can be obtained by AutoCAD. The developed system will be useful in reducing trial and error of design engineers in determining the diameter and height of the initial cylindrical billet from the final product geometry and the intermediate necessary sequences.

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Quantitative Analysis of Effect of Shrink Fit in Cold Forging (냉간단조에서 금형 열박음 영향의 정량적 분석)

  • Li, Qiushi;Kim, Min-Cheol;Jung, Dong-Chan;Son, Yo-Hun;Joun, Man-Soo
    • Journal of the Korean Society for Precision Engineering
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    • v.28 no.3
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    • pp.301-307
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    • 2011
  • In this paper, effects of major design parameters of cold forging dies on die mechanics are quantitatively investigated with emphasis on shrink fit using a thermoelastic finite element method. A ball-stud cold forging process found in a cold forging company is selected as a test process and the effects of die insert material, magnitude of shrink fit, dimension of shrink ring, number of shrink rings, partition of die insert and clamping force on effective stress and circumferential stress are analyzed. It has shown that the number of shrink rings, magnitude of shrink fit, and Young's modulus of die insert material have strong influence on compressive circumferential stress in die insert but that the influence of the other design parameters is relatively weak.