• Title/Summary/Keyword: Progressive Stamping

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Design of Strip Bridge for Unsymmetrical Progressive Stamping for an Automotive Seat Side Cushion Pane (자동차 시트 사이드 쿠션 패널의 비대칭 프로그레시브 스탬핑 성형을 위한 스트립 브릿지 설계)

  • Hong, S.;Joung, C. S.;Choi, B. S.;Lee, D. Y.
    • Transactions of Materials Processing
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    • v.24 no.6
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    • pp.400-404
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    • 2015
  • For mass production of stamped parts, which require complicated in-press operations, it is always advisable to use a progressive die set. It is difficult to choose a progressive die set if the stamped parts need to be deep drawn and especially if they are unsymmetrical. Because unsymmetrical deep drawing parts are very sensitive to the effect of weight during moving to the next step, they are hard to exactly locate on the die face. An automotive seat side cushion panel is about 80mm high, unsymmetrical and its low edge needs hemming, so it is hard to produce even using a progressive die set. In the current paper a progressive stamping for seat side cushion panel was examined. Five strip bridges were considered to be strong enough to move to the next die as predicted by the CAE analysis.

Experimental Study on Mixed-Model Production of Stator and Rotor using Motor Core Laminated Stamping Die Technology for Attaching and Detaching Cam (Cam 착탈 방식의 모터코어 적층금형 기술을 적용한 Stator와 Rotor의 다종 혼류 생산에 대한 연구)

  • Park, D.H.;Hwang, P.J.
    • Transactions of Materials Processing
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    • v.26 no.4
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    • pp.240-245
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    • 2017
  • Mixed-model production technology is a method of producing multiple products with one production process and production line in order to reduce wasted manpower and adjust to market trends. In other words, mixed-model production is a flexible production system that changes production volume by model according to market demand. This study has developed a progressive laminated stamping die technology to enable flexible production of a motor core consisting of attaching and detaching the Cam on the back of the punch so that two kinds of stator and two kinds of rotor could be produced in one progressive die.

Stamping Tool Wearing Analysis by Time-Frequency Analysis (시간-주파수 분석에 의한 금형 마모 분석)

  • Lee, Chang-Hee;Han, Ho-Young;Seo, Geun-Seok;Kim, Yong-Yun
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.19 no.3
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    • pp.407-413
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    • 2010
  • This paper reports on the research which analyzes acoustic signals acquired in progressive compressing, hole blanking, and burr compacting process. An acoustic sensor was set on the bed of hydraulic press. Acoustic signal is generated from progressive stamping process. First the signal acquired from the unit process; compressing, blanking or compacting, is studied by Fourier Transform and Short Time Fourier Transform. The blanking process emitted ultrasonic signal with more than 20kHz, but the compressing and compacting processes emitted acoustic signals with lower than 10kHz. The combined signals periodically acquired right after the tool grinding were then analyzed. 70-80kHz signals appeared in time-frequency domain, but not in the frequency domain, the magnitude of which was related to the tool wear. Short Time Fourier Transform made up for the Fourier Transform in analyzing the emitted signal for stamping process in the ultrasonic domain.

A Development of the Design System of the Progressive Stamping Dies by using Boundary Representation and Its Application (경계표현법을 응용한 순차 금형 자동 설계시스템 개발 및 적용)

  • Kim Yong Yun
    • Journal of the Korean Society for Precision Engineering
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    • v.22 no.2
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    • pp.126-132
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    • 2005
  • In this paper, an auto-design system is introduced for a stamping tool based on commercial computer aided design system with its drafting language. The auto-design system consists of tool oriented product design subsystem which modifies and configures the product drawing, tool concept design subsystem which make a design of the punches and their punching progression and parts design subsystem that makes automatic dimension. The system is applied to the mechanical design of the stamping tool. The main logic of the system is based on half-edge theory, a kernel for the 3 dimensional CAD system, which is applied to 2 dimensional drafting auto-design system. The auto-design system enables to conspicuously reducing the designing time of the tool. In addition, there is little drafting error that had been about 3% without auto design program. It is effective to reduce the development time for new products because of rapid designing time of the tools, standardization of the stamping tool and the drafting rule for the auto-design system. The auto-design system yields high efficiency of the tool manufacturing system.

Quantitative Evaluation of Wear Resistance of Stamping Tool with Respect to Hardness of Tool Materials in Cold Stamping of TRIP1180 Steel Sheets (TRIP1180 판재의 냉간 스탬핑공정에서 금형강의 경도 특성에 따른 내마모성 평가)

  • Bang, J.H.;Bae, G.;Song, J.H.;Kim, H.G.;Lee, M.G.
    • Transactions of Materials Processing
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    • v.31 no.3
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    • pp.129-135
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    • 2022
  • The purpose of this study was to quantitatively evaluate the influence of hardness of tool materials on wear resistance in the sheet metal forming process. Punches used in the wear test were made of STD-11 and K340 tool material, and the tempering temperature was set to 530℃ and 500℃, respectively, to control the hardness of the tool materials. The punches mimic the shape of stamping tool of automotive body component to reflect its plastic deformation, and are designed to concentrate wear on the curvature region of punches. Progressive die and coil sheet were used to save time, cost, and raw sheet materials. By quantitatively measuring the wear depth of the punches, the wear behavior and mechanism of the punches were investigated, and characteristics of hardness and wear resistance according to tool materials and tempering temperatures were evaluated. Testing results indicate that the punch made of K340 tool steel with higher hardness had better wear resistance than that of STD-11 tool steel, and the hardness and wear resistance of tool steel were significantly impacted by the tempering temperature.

A Study on the Complex Automation Die Manufacturing Technology for an Automotive Seat Cushion Panel (자동차 시트 쿠션 판넬의 복합 자동화 금형 제조기술에 관한 연구)

  • Park, D.H.;Jung, C.S.
    • Transactions of Materials Processing
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    • v.23 no.2
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    • pp.75-81
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    • 2014
  • Progressive dies are used for metal stamping during which multiple operations are performed in a sequence. Material is fed automatically from a coil into the press and advances from one die station to the next with each press stroke. Transfer dies are used in high-volume manufacturing for round, deep-drawn, and medium-to-large parts. Several different operations may be incorporated within a transfer die such as blanking, bending, piercing, trimming, and deep drawing. The main challenge in the current study is how to deform a seat cushion panel meeting the design specifications without any defects. A complex automation die manufacturing technology for the automotive seat cushion panel, mixing both semi-progressive die and transfer die for continuous production, was developed.

Development of Combined Sheet Metal Forming and Plate Forging of a Metal Seal Part of Hub Bearing for an Automobile (자동차 허브 베어링용 씰 금속부품의 판재성형 및 판단조의 복합성형 공정 개발)

  • Park, K.G.;Moon, H.K.;Oh, S.K.;Joun, M.S.
    • Transactions of Materials Processing
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    • v.29 no.4
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    • pp.194-202
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    • 2020
  • In this paper, experimental and numerical study on a combined sheet metal forming and plate forging of a seal part of a passenger car's hub bearing is conducted to develop the new process of which target is to remove machining process by plate forging and to achieve near-net shape manufacturing. The previous process of a sheet metal forming inevitably needed a machining process for making stepped sheet after conventional sheet metal forming in a progressive way. The stepped sheet is intended to be formed by plate forging in this study. Through the systematic way of developing the combined forming process using solid elements based-elastoplastic finite element method (FEM), several conceptual designs are made and an optimized process design in terms of geometric dimensioning and tolerance of straightness of the thin part is found, which is exposed to bending in metal forming of axisymmetric part. The predicted straightness measured by the slope angle of the tilted thin region is compared with the experimental straightness, showing that they are in a good agreement with each other. Through this study, a systematic approach to optimal process design, based on elastoplastic FEM with solid elements, is established, which will contribute to innovating the conventional small-scaled sheet metal forming processes which can be dealt with by solid elements.

Development of Perforating Die for Manufacturing Fine Multi-perforated type Nail Files (미세 다수공 타입의 네일파일 제조용 퍼퍼레이팅 금형 개발)

  • 김세환
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.5 no.4
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    • pp.309-314
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    • 2004
  • 0.5mm thick steel is used to manufacture nail files. The first process is blanking and the second process is making about 300 holes of 0.8-l.0mm in diameter. This process depends mainly on etching which takes 33% of manufacturing cost and it can make manufacturing cost rise. The residual etching reagent is not environmentally friendly and the steel material is apt to rust as well. To solve these problems, researches on the following subjects are performed: proper material to prevent from rusting and strip layout strategies in stamping to replace etching process with press process which makes use of die. And new quill type punch is developed to replace the regular standard punch, one of the die parts, which frequently get broken while working. And these researches and developments lead to develop a progressive perforating die.

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Characterization of Acousto-ultrasonic Signals for Stamping Tool Wear (프레스 금형 마모에 대한 음-초음파 신호 특성 분석)

  • Kim, Yong-Yun
    • Transactions of the Korean Society for Noise and Vibration Engineering
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    • v.19 no.4
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    • pp.386-392
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    • 2009
  • This paper reports on the research which investigates acoustic signals acquired in progressive compressing, hole blanking, shearing and burr compacting process. The work piece is the head pin of the electric connector, whose raw material is the preformed steel bar. An acoustic sensor was set on the bed of hydraulic press. Because the acquired signals include the dynamic characteristics generated for all the processes, it is required to investigate signal characteristics corresponding to unit process. The corresponding dynamic characteristics to the respective process were first studied by analyzing the signals respectively acquired from compressing, blanking and compacting process. The combined signals were then periodically analyzed from the grinding to the grinding in the sound frequency domain and in the ultrasonic wave. The frequency of around 9 kHz in the sound frequency domain was much correlated to the tool wear. The characteristic frequency in the acoustic emission domain between 100 kHz and 500 kHz was not only clearly observed right after tool grinding but its amplitude was also related to the wear. The frequency amplitudes of 160 kHz and 320 kHz were big enough to be classified by the noise. The noise amplitudes are getting bigger, and their energy was much bigger as coming to the next regrinding. The signal analysis was based on the real time data and its frequency spectrum by Fourier Transform. As a result, the acousto-ultrasonic signals were much related to the tool wear progression.