• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.4
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• pp.126-133
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• 2015

To enhance the productivity and quality of the compound process of progressive dies and transfer dies, the semi-progressive method is applied in the material supply step to produce blanks, and then the transfer method is applied. Parts are transferred among processes by means of the finger and transfer bar in the transfer die, and the final seat cushion panel is produced. The main challenge in the current study is how to deform a seat cushion panel while meeting the design specifications without any defects. In order to obtain this technology, a sheet metal-forming simulation and die forming of the seat cushion panel were adopted; as a result, a compound die-forming technology for the automotive seat cushion panel, combining both semi-progressive die and transfer die for continuous production, was successfully developed.

• Agricultural and Biosystems Engineering
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• v.6 no.1
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• pp.27-33
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• 2005

Soy protein meat analog was produced using a twin-screw extruder attached with a cooling die. Heat transfer analysis was performed for cooling dies with various die sizes at the four different moisture contents of feed during extrusion process. The experimental design consisted of two cooling die widths (30 and 60 mm), three cooling die lengths (100, 200, and 300 mm), four product moisture contents (71.2, 67.0, 61.6 and 55.8%), and water and water plus ethylene glycol as cooling material. When water was used as cooling medium, the values of equivalent overall heat transfer coefficient $(U_e)$ for each die width of 30 and 60 mm were in the range of 187.0 - 341.4 and $358.5-191.6W/m^2^{\circ}C$ depending on the size of die length. Convective heat transfer coefficients between cooling water and inside die wall of cooling channel $(h_c)$ for both die widths of 30 and 60 mm were 588.5, 416.1, and $339.8W/m^2^{\circ}C$ for each die length of 100, 200, and 300 mm. Convective heat transfer coefficients between product and inside die wall of product channel $(h_p)$ for each die width of 30 and 60 mm were in the range of $434.6-888.1W/m^2^{\circ}C$ and $460.7-1014.5W/m^2^{\circ}C$ depending on the size of die length. When water plus ethylene glycol was used as cooling medium, the values of $U_e$ were in the range of $143.9-319.6W/m^2^{\circ}C$ and $177.8-332.7W/m^2^{\circ}C$ for each die width of 30 and 60 mm depending on the size of die length.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.391-394
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• 2006

In this paper, a criterion on enclosed die forging with a double action link type hydraulic die set is presented. Operational principle of the die set in enclosed die forging is introduced with emphasis on force transfer from the press and the hydraulic system to the material through links, die components and punches. Force transfer mechanism is examined and three different modes are introduced. Requirements on force equilibrium are applied to the three force transfer modes and a criterion on enclosed die forging with a double action link type hydraulic die set is drawn. The criterion is discussed to minimize forming load.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.26-35
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• 2003

This study explains the effects of lubricant and surface treatment on hot forging die life. The mechanical and thermal load, and thermal softening which is happened by the high temperature of die, in hot and warm forging, cause die wear, heat checking and plastic deformation, etc. This study is fur the effects of solid lubricants and surface treatment condition for hot forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatment and lubricant are very important to improve die life for hot forging process. The main factors, which affect die hardness and heat transfer, are surface treatments and lubricants, which are related to thermal diffusion coefficient and heat transfer coefficient, etc. For verifying these effects, experiments are performed for hot ring compression test and heat transfer coefficient in various conditions as like different initial billet temperatures and different loads. The effects of lubricant and surface treatment for hot forging die life are explained by their thermal characteristics. The new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.299-302
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• 2003

The interface heat transfer coefficient was measured for non-isothermal bulk forming of Ti-6Al-4V. FE analysis and experiments were conducted. Equipment consisting of AISI H13 die was instrumented with thermocouples located at sub-surface of the bottom die. Die temperature changes were investigated in related to the process variables such as reduction, lubricant and initial die temperature. The calibration approach based on heat conduction and FE analysis using an inverse algorithm were used to evaluate the interface heat transfer between graphite-lubricated die and glass-coated workpiece. The coefficients determined determined were affected mainly by the contact pressure. The validation of the coefficients was made by the comparison between experimental data and FE analysis results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.1146-1149
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• 1995

The CAD/CAM System for deep drawing transfer die in mechanical press proess has been developed. The developed CAD system can generate the drawing of drawing of transfer die in mechanical press. Using these results from CAD system, it can generate the NC data to machine die's elements on the CAD system. This system can reduce design man-hours and human errors. In order to construct the system, it is used to automate the design process using knowledge base system. The developed system is based on the knowledge base system which is involved a lot of expert's technology in the practice filed. Using AutoLISP language under the AutoCAD system, CTK customer language of SmartCAM is used as the overall CAD/CAM environment. Results of this system will be provide effective aids to the designer and mannufacturer in this field.

• Transactions of Materials Processing
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• v.12 no.4
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• pp.370-375
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• 2003

Determination of the interface heat transfer coefficient was investigated in non-isothermal bulk forming of glass-coated Ti-6Al-4V. FE analysis and experiments were conducted. Equipment consisting of AISI Hl3 die was instrumented with thermocouples located at sub-surface of the bottom die. Die temperature changes were investigated in related to the process variables such as reduction, lubricant and initial die temperature. The calibration approach based on heat conduction and FE analysis using an inverse algorithm were used to evaluate the interface heat transfer between graphite-lubricated die and glass-coated workpiece. The coefficients determined were affected mainly by the contact pressure. The validation of the coefficients was made by the comparison between experimental data and FE analysis results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.833-836
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• 2000

The mechanical and thermal load. and thermal softening which is happened by the high temperature of die, in hot and warm forging, cause wear. heat checking and plastic deformation, etc. This study is for the effects of solid lubricants and surface treatments for warm forging die Because cooling effect and low friction are essential to the long lift of dies. optimal surface treatments and lubricants are very important to hot and warm forging Process. The heat that is generated by repeated forging processes. and its transfer are important factors to affect die life. The main factors, which affect die hardness and heat transfer, are surface treatments and lubricants, which are related to thermal diffusion coefficient and heat transfer coefficient, etc. For verifying these. experiments art performed for diffusion coefficient and heat transfer coefficient in various conditions - different initial billet temperatures and different loads. Carbonitriding and ionitriding are used as surface treatments. and oil- base and water-base graphite lubrirants are used. The effects of lubricant and surface treatment for warm forging die lift are explained by their thermal characteristics.

• Transactions of Materials Processing
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• v.22 no.2
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• pp.101-107
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• 2013

The heat transfer characteristics between die and sheet and die and coolant are important parameters in hot press forming process. The determination of the quenching time that guarantees full martensitic transformation requires proper understanding of these heat transfer characteristics. The contact area changes drastically during the quenching process due to volume changes of both die and sheet by temperature drop as well as phase transformation. Several types of modeling techniques are tested in order to select the most suitable. The effect of quenching time as well as die heat conductivity on martensitic transformation is investigated and predictions are compared to experimental results.