• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.162-166
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• 2003

In combined forward-backward extrusion with controlled forward speed by a counter punch, accurate parts with forward rod can be formed. As an extension of this method, reverse extrusion is proposed, in which the extruded forward rod is pushed back while the main punch is kept at the final position after the forward-backward extrusion process. The experiment is carried out using lead as a model material. With the reverse extrusion method, longer forward rods can be formed without under-filling defect than that by combined extrusion with controlling extrusion speed.

• Journal of Power System Engineering
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• v.15 no.6
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• pp.53-58
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• 2011

To optimization of mlod for fineblanking forming of sector gear of recliner, it was analyzed the effect of clearance, V-ring height, V-ring position, blank holding force and counter punch force. In case of 0.003 mm of clearancs, the finest shear plane was obtained, but optimization between die and punch clearance was 0.005 mm. The height of V-ring was 0.7 mm. In case of increasing of hold force, the size of shear plane got better and the decrement of thickness became smaller. Both the size of shear plane and the decrement of thickness increased according to increasing of counter punch force.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.6 s.183
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• pp.52-56
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• 2006

Punching tools like an electrodes are made by milling or etching or EDM. These methods had time consuming, low efficiency and air pollution. So, we have developed a shearing device which counter punching method for burrless cutting of micro wire. Using the straightened SUS304 wire with $200{\mu}m$ diameter, we confirmed the tendency of the shear plane for punch tools. It was impossible to completely remove the bun in the shearing process. In order to minimize the burr size and fine shear plane, we have accomplished the various experiment conditions such as the U-groove, the effect of the counter punch, shear angle and clearance. The results of the experiments show that indentation, slip plane and bent shape were related to the shear angle and clearance.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.4
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• pp.26-33
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• 2002

One characteristic of Fine-Blanking is that the size and the direction of stress and strain are very complex in the plastic flow according to the condition of blanking. Especially, they are affected by the clearance of punch and die, by the force of blanking holder and by the force of counter punch. The purpose of this research is to how the deformation behavior in shear zone more clearly, based on Green & Cauch's large deformation theory. The deformation behavior and cracks were investigated in each step of shear, according to punch penetration increase, the use of V-indenter ring and the hardness of materials. This research found that the transforming behavior was the same as pure discretion and the cracks could be prevented when hardness is low.

• Transactions of Materials Processing
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• v.15 no.3 s.84
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• pp.226-231
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• 2006

The fuel injector is a pa.1 that controls the fuel supply of automotive engine. The housing of the fuel injector supports the rod, the needle valve and the solenoid. In this study, the rigid-plastic FE-analysis by using the design of experiments (DOE) and the response surface methodology (RSM) has been performed to produce the product reducing the under-fill and the maximum effective strain. From the results of DOE, the stem of counter punch and the face angle of punch at the $1^{st}$ process, and the stem of punch at the $2^{nd}$ process were determined as the significant design variables far each response such as the upper under-fill, lower under-fill and the maximum effective strain. From the results of RSM, the optimal values of the design variables have been also determined by simultaneously considering the responses.

• Transactions of Materials Processing
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• v.30 no.3
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• pp.149-156
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• 2021

Fine blanking is a high-precision process combining principles of metal stamping and cold forming. Unlike conventional metal stamping, fine blanking uses a special triple action such as V-ring force, counter force, shearing force. This study performed the effect of pocket-shaped compression molding on the mold life of the fine blanking using the 7.4mm thick SM45C material. In order to determine the lifespan of the punch and die in the fine blanking molds, a trial mold was manufactured and various punch materials were selected to perform the mold life test. A study on the life of a fine blanking mold by applying a thick plate material was experimentally performed through a mold test.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.7
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• pp.1340-1347
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• 2002

Finite element simulations are being widely used to increase the efficiency and effectiveness of design of bulk metal forming processes. In such simulations, proper consideration of friction condition is crucial in obtaining reliable results. For this purpose, tip test based on backward extrusion was proposed recently. In this lest, a cylindrical billet is positioned in a shallow groove of a counter punch for centering purpose and formation of a radial tip is induced on the extruded end of the workpiece. In this study, the effect of centering groove on tip test was investigated. The quantitative ratio of the shear friction factors between the punch and die was numerically determined depending on the shape of centering groove. Also, surface expansion and pressure distribution along the punch and die were considered in order to better understand the reason that friction condition at the punch compared to the one of die was more severe.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.158-161
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• 2003

Extrusion of forward-gear and backward-rod by combined extrusion with controlling the extrusion velocity using a counter tool is studied. In the combined forward-backward extrusion with controlling extrusion velocity, only parts with short gear can be formed. To obtain longer gear parts, extrusion with reverse ram motion is carried out after the combined forward-backward extrusion process. In this method, combined forward-backward extrusion is carried out until excessive extrusion length is attained and then, the motion of the punch is stopped and the counter tool is moved in the inverse direction and returned to the position for obtaining the desired extrusion length. The experiment is carried out by using lead for billets as a model material. With reverse ram motion, longer gear teeth without under-filling defect can be formed than that by only combined extrusion with controlling extrusion velocity.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.5 no.3
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• pp.51-57
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• 2006

Hydro-mechanical punching was developed for preventing burr formation. Circular hole punching and Finite element method(FEM) analysis were conducted to investigate shearing characteristics of this process in comparison with conventional and mechanical counter punching. In this process hydrostatic pressing with appropriate medium was utilized instead of counter punch, which resulted in the delay of the point that the fracture is initiated and clean shearing surface was obtained. FEM analysis was utilized to find out optimum processing parameters and shearing mechanism for burr-free hole punching.

• Journal of Industrial Technology
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• v.25 no.B
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• pp.121-126
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• 2005

Micro wires manufactured by the straightening process are used in the BT(Bio-Technology), IT(Information-Technology), NT(Nano-Technology). We have developed a novel wire straightener which uses the direct heating method(DHM) for straightening the micro wire and shearing device for burr-less cutting. In this study, we confirm the tendency of micro wire after the shearing process. It is impossible to remove the burr in the shearing process. However, the embodiment of minimum burr size after the shearing process is the best in-process method. In order to minimize the burr size, we have accomplished the various experiment condition such as the U-groove, the effect of the counter punch, the shear angle, clearance.