• Transactions of Materials Processing
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• v.17 no.2
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• pp.124-129
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• 2008

Net shape forging technologies give many effects into the costs and qualities for the finished products. So, the studies to reduce the additional machining amount are very important in forging industry. Specially, there are two main topics in cold forging industry, such as, tool life and precision forging. In this study, new forging technique was proposed to eliminate the machining process for fixing up the length and improve the lead accuracy of gear. The luck-up hub is manufactured through many processes, such as upsetting, piercing and direct extrusion. The gear is formed in direct extrusion process; however, lead accuracy of the gear is over allowance limit. Therefore, the additional sizing process must be added. In this study, process design for closed-die forging of a lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Structural Engineering and Mechanics
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• v.75 no.3
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• pp.369-376
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• 2020

The life of conventional steel plastic injection molds is long but manufacturing cost and time are prohibitive for using these molds for producing prototypes of products in limited numbers. Commonly used 3D printers and rapid prototyping methods are capable of directly converting the digital models of three-dimensional solid objects into solid physical parts. Depending on the 3D printer, the final product can be made from different material, such as polymer or metal. Rapid prototyping of parts with the polymeric material is typically cheaper, faster and convenient. However, the life of a polymer mold can be less than a hundred parts. Failure of a polymeric mold during the injection molding process can result in serious safety issues considering very large forces and temperatures are involved. In this study, the feasibility of the inspection of 3D printed molds with the surface response to excitation (SuRE) method was investigated. The SuRE method was originally developed for structural health monitoring and load monitoring in thin-walled plate-like structures. In this study, first, the SuRE method was used to evaluate if the variation of the strain could be monitored when loads were applied to the center of the 3D printed molds. After the successful results were obtained, the SuRE method was used to monitor the artifact (artificial damage) created at the 3D printed mold. The results showed that the SuRE method is a cost effective and robust approach for monitoring the condition of the 3D printed molds.