• 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.

• 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.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1570-1575
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• 2007

The cold-forging process analysed in this paper deals with the cam bolt of a nonaxisymmetric shape which mainly is used as a part in the steering system of a vehicle for the purpose of adjusting shock absorb. So both strength and endurance are very important for the cam bolt. In this study, cam bolt forging process is composed of four stage processes. For three forging stages, shape of workpiece will be eccentrical. And then bolt head and washer of eccentrical shape is created in last stage. 3D finite element analysis repeatedly has been performed with changing dimension of die to obtain adequate former multi forging process and die shape. Simulation results reviewed have influence on deciding design of die and forging process. As a result, Simulation results have provided a direction to improve the process.

• 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.

• Journal of Advanced Marine Engineering and Technology
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• v.33 no.1
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• pp.97-103
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• 2009

The process design of forward Extrusion and Upsetting of Axi-symmetric part has been studied in this paper. During the cold forging product; auto transmission Solenoid Valve part, the defects such as folding and under-fill can be appeared by the improperly controlled metal flow. In this study, to reduce the folding and under-fill the design of experiments has been used to find out the significant design variables in the design of forging process. This paper deals with an Process Planning with which designer can determine operation sequences even after only a little experience in Process Planning of Multi-Former products by multi-stage former working. The approach is based on knowledge-based rules, and a process knowledge-base consisting of design rules is built. Based on the systematic procedure of process sequence design, the forming operation of cold forged auto transmission Solenoid Valve part is analyzed by the commercial Finite Element program, DEFORM/2D.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.8
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• pp.2039-2052
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• 1994

In this study, an expert system for multi-stage cold forging process design of axisymmetric parts is developed. The available geometries are axisymmetric shape and cylinder with a hold in one end. The overall system is composed of knowledge-based system for process sequence design, output module interfaced with CAD system and material data-base. In the developed system, designed process can be modified in order to reduce the number of processes and make the distribution of forming load be almost equal at various deforming stages within the machine capacity. After process sequence design is completed, results can be stored as a text file or a commercial CAD system file. The capabilities of the developed system are illustrated through various examples of process design.

• Journal of the Korean Society for Precision Engineering
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• v.6 no.4
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• pp.84-93
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• 1989

This paper describes some development of Computer-Aided Process Planning System for cold-forging of rotationally symmetric parts(soild shape and solid-can combined shape) produced by the presses or formers. Using the developed system, forming sequences for producing final product are generated as graphic forms and process names, preform dimensions and process parameters(load, punch pressure, die pressure) are generated as routing sheets. Konwledges for forming sequence and process parameters are extracted from process limitations, plasticity theories, handbooks, relevent refferences and empirical know-how of experts in cold forging companies. Among extracted knowldeges, general and consistent knowledges are represented as design rules and are constructed as knowledge base. The developed system provides more powerful tool for through checking the producibilities of design, conformation of appropriate forming sequences and discoveries of new possibility. The results of the developed system are in good agreement with the practical data.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.2
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• pp.331-336
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• 2012

This study was aimed at the design of the dies for the guide valve for the fuel pressure regulator using the computer simulation to shorten the period of production, on the basis of the process planning which was designed by the field experts. In the computer simulation, 'Deform-3d' and 'Eesy-DieOpt' have been used, which are the commercial process analysis and die design program. Through the process analysis, we could know the propriety of the forming process, the inner pressure of the die and the suitable fitting pressure between the insert and the sleeve which was not showing any positive tangential stresses in the insert. Through the simulation of die design, we could know the number of the stress ring, the diameter ratios, the stresses of the die, the shrink fitting tolerance and temperature in the condition of the already determined maximum outer die diameter of the multi-stage former. The validity of the die design using the computer simulation was analyzed by the experiments and the results were satisfactory. As the results of this study, the new and easy die design system for multi-forging has been developed.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.5
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• pp.582-588
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• 2011

This study was aimed at the design of the dies for the unified shaft joint using the computer simulation to shorten the period of production, on the basis of the process planning which was designed by the field experts. In the computer simulation, 'Deform-3d' and 'Eesy-DieOpt' have been used, which are the commercial process analysis and die design program. Through the process analysis, we could know the propriety of the forming process, the inner pressure of the die and the suitable fitting pressure between the insert and the sleeve which was not showing any positive tangential stresses in the insert. Through the simulation of die design, we could know the number of the stress ring, the diameter ratios, the stresses of the die, the shrink fitting tolerance and temperature in the condition of the already determined maximum outer die diameter of the multi-stage former. The validity of the die design using the computer simulation was analyzed by the experiments and the results were satisfactory. As the results of this study, the new and easy die design system for multi-forging has been developed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.86-89
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• 2000

In cold forging by multi stage former, crowing process is important process for the high production rate and automation of forging process. But various cropping defects occur in cropping process such as orthogonality, ovality and unevenness, etc. These defects have harmful effects on the dimensional tolerance of products and tool life. So in this study, the cropping experiment is performed to examine influence of cropping process variables(clearance, cutting velocity, H/D) on occurrence of crowing defects and optimum process variables are selected, and then FE analysis is performed to verify influence of these defects on dimensional tolerance and tool life.