• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.277-280
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• 2005

A shape optimization is applied to achieve a design objective in three-dimensional forging processes. In multi-stage forging processes, among the important design aspects, the die shape fur preforming is regarded as the design variable since it influences the forged part relatively higher than the others. The rigid-plastic finite element method and the sensitivity method are employed and formulated to solve a formulated optimization problem. An approximation scheme is also used for the direction search during the optimization. The upset forging of a square box is selected as a test example in order to demonstrate and verify the optimization process of this study. After the optimization, the optimized shape of the die yields a finial product of desire shape.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1994년도 추계학술대회 논문집
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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.

• 소성∙가공
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• 제12권6호
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• pp.536-541
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• 2003

In this paper, the rigid-viscoplastic finite element method is employed together with an iteratively force-balancing method to analyze a piercing and trimming process with a spring-attached die in hot former forging. An actual piercing and trimming process with a spring-attached die is investigated in detail and a generalized analysis model is proposed. A multi-stage hot former forging process is simulated under various spring constants. The analyzed results are discussed in order to investigate the effects of spring constants on the metal flow lines and the formed shapes. Then an optimal piercing and trimming process in hot former forging is devised.

• Journal of Advanced Marine Engineering and Technology
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• 제33권1호
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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.

• 한국생산제조학회지
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• 제21권2호
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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.

• 한국생산제조학회지
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• 제20권5호
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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.

• 한국정밀공학회지
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• 제15권4호
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• pp.118-124
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• 1998

The die wear is one of the main factors affecting die accuracy and tool lifetime. It is desired to reduce die wear by developing simulation method to predict wear based on process variables, and then optimizing the process. Therefore, this paper describes methodology of preform design for minimizing wear of finisher die in multi-stage cold forging processes. The finite element method is combined with the routine of wear prediction. The cold forging process is analyzed using developed simulation method. In order to obtain preform to minimize die wear, the Flexible Polyhedron Search(FPS) algorithm is used. The optimal preform shape is found from iterative deformation analysis and wear calculation.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.199-202
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• 2005

In this paper, the six sigma scheme is employed together with the rigid-viscoplastic finite element method to obtain the optimal metal flow lines in hot press forging. In general, the six sigma process is consisted of following five steps : define, measure, analyze, improve and control. Each step Is investigated in detail to meet customer's requirements through improvement of product quality. A forging simulator, AFDEX-2D, is used for analysis of the metal flow lines of a multi-stage hot forging process under various conditions of major factors, determined at each step of the six sigma process. The analyzed results are examined in order to reveal the effects of major factors on the metal flow lines and the formed shapes. The effects are used to find an optimal process and the optimal process with die is devised and tested. The comparison between required metal flow lines and experiments shows that the approach is effective for optimal process in hot forging design considering metal flow lines.

• Journal of Advanced Marine Engineering and Technology
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• 제33권2호
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• pp.295-303
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• 2009

Forging of square spline was investigated by using finite element methods in this study. Spline is widely used by torque transmitter in the fields of automobile, aircraft, and shipping etc. Friction on the surface of die is regarded as the most important factor to improve the dimensional accuracy for complete forming of spline teeth. Finite element simulation was carried out to improve the formability of the spline, especially remove unnecessary burrs which were extruded in gap between the die and the punch. To remove the burrs, various friction factors are considered on the surfaces of the die in the simulations and punch flat surface was designed. The simulated results were compared with experimental ones. As a results, it is possible to control the growth of burrs and improve formability of spline teeth by applying various friction factors and design of punch flat surface.

• 한국정밀공학회지
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• 제28권3호
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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.