• Title/Summary/Keyword: progressive dies

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Development of Rotary Transfer Forming Device for Process Reduction in Forming (프레스 공정 단축을 위한 회전식 트랜스퍼 성형장치 개발)

  • Kim, Seung-Gi;Youn, Jae-Woong
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.23 no.5
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    • pp.413-420
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    • 2014
  • Although the transfer forming process has various advantages, it is also inefficient for the use of multiple press machines, especially for small part sizes. In this study, a new forming process was proposed to use multiple tandem dies in a single press machine. A rotary transfer forming device was developed to combine the advantages of the progressive and transfer forming process. In this study, a detailed forming process using this device was analyzed, and the device was designed to perform four series of tandem forming processes in a single press. In order to analyze the feasibility of this forming process, simple forming dies were made. As a result, the position accuracy was 4 arcsec, and the forming speed reached up to 20 strokes per minute. It is thought that this rotary transfer forming device can help to save initial setup costs through the more efficient use of space in a press machine.

Development of High Precision R/F Switch Connector Shell for Mobile Phone by Embossing and Burring Process (엠보싱 및 버링 공법을 이용한 휴대폰용 초정밀 알 에프 스위치 커넥터 쉘 개발)

  • Choi, H.S.;Shin, H.J.;Kim, B.M.;Ko, D.C.
    • Transactions of Materials Processing
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    • v.22 no.6
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    • pp.317-322
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    • 2013
  • A radio frequency(R/F) switch connector is widely used in wireless devices such as mobile phone and navigator to check defects of the circuit board of product. The R/F switch connector shell plays a role in protecting the switch connector. Previously, this part was machined using a turning, which is time-consuming and has poor material utilization. Furthermore, the workpiece material of brass containing lead that has excellent machinability has environmentally regulated during recent years. The purpose of the current study was to develop the connector shell by forming through progressive dies including embossing, burring and forging process in order to achieve higher productivity and dimensional accuracy without tool failure. To accomplish this objective, a strip layout was designed and finite element (FE) analysis was performed for each step in the process. Try-out for the connector shell was conducted using progressive die design based on FE-analysis results. Dimensional accuracy of developed part was investigated by scanning electron microscopy. The result of the investigation for the dimensions of the formed connector shell showed that the required dimensional accuracy was satisfied. Moreover, productivity using the progressive die increased four times compared to previous machining process.

Structural analysis of the Micro-Former based on results from the forming analysis for milli components (밀리부품 성형해석을 통한 Micro-Former의 거동해석)

  • Yoon J.H.;Huh H.;Kim S.S.;Choi T.H.;Na G.H.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2004.05a
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    • pp.118-121
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    • 2004
  • Manufacturing process for milli components has recently gained researcher's focus with the increasing tendency toward highly integrated and micro-scaled parts for electronic devices. The milli-components cannot be formed by the conventional manufacturing process since the parts require higher dimensional accuracy than the conventional ones. In order to enhance the forming accuracy and productivity, various forming procedures proposed and studied by many researchers. In this paper, forming analysis of milli-components has been studied with a new micro-former. In modeling of progressive dies, multi-stage forming sequence has been analyzed with finite element analysis by LS-DYNA3D. The analysis proposes the sequential die and part shapes with the corresponding punch force and dimensional accuracy. The analysis also considers the effect of elastic dies on the dimensional accuracy of the formed parts. The analysis result demonstrates that the elastic analysis in the milli-forming process is indispensable fur accurate forming analysis. The analysis procedure in the paper will provide good information in design of a new micro-former and milli-component.

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Improvement of Switch Box Manufacturing Process and Development of Handling Mechanism (스위치박스 제조공정 개선과 핸들링 장치 개발)

  • 김세환;이은종;김현효;유정봉
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.4 no.1
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    • pp.31-35
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    • 2003
  • Switch box is metal box and used for electric wire pipe in building. In manufacturing switch box, we need 5∼6 press machines, 5∼6 dies, 1 tapping machine. and 7∼8 operators. What matters is rise of manufacturing cost and operators' reluctance of working. To solve this problem, we modified the pre-existing die and developed handling mechanism, which leads to improve the manufacturing process. After the research and development, we could reduce the number of machines and workers needed in the process; 2 press machines, 2 dies, 1 tapping machine, and 1 operator. That means we can save labor and the number of operators needed, reduce manufacturing cost, and get the effect of import replacement.

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Multi-Stage Forming Analysis of a Milli-Component for Improvement of Forming Accuracy (밀리부품의 정밀도 향상을 위한 다단계 성형 및 금형 해석)

  • Yoon, J.H.;Huh, H.;Kim, S.S.;Na, G.H.;Park, H.J.;Choi, T.H.
    • Transactions of Materials Processing
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    • v.13 no.5
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    • pp.429-434
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    • 2004
  • Manufacturing process for milli components has recently gained researcher's focus with the increasing tendency toward highly integrated and micro-scaled parts for electronic devices. The milli-components need more precise manufacturing process than the conventional manufacturing process since the parts require higher dimensional accuracy than the conventional ones. In order to enhance the forming accuracy and productivity, various forming procedures proposed and studied by many researchers. In this paper, forming analysis of milli-components has been studied with a new micro-former. In modeling of progressive dies, multi-stage forming sequence has been analyzed with finite element analysis by LS-DYNA3D. The analysis proposes the sequential die and part shapes with the corresponding punch force and dimensional accuracy. The analysis also considers the effect of elastic dies on the dimensional accuracy of the formed parts. The analysis result demonstrates that the elastic analysis in the milli-forming process is indispensable for accurate forming analysis. The analysis procedure in the paper will provide good information in design of a new micro-former and milli-component

A Study on the Optimal Molding Conditions for Aspheric Glass Lenses in Progressive GMP (순차이송형 유리렌즈 성형공정에서 비구면 유리렌즈의 최적 성형조건 연구)

  • Jung, Tae-Sung;Park, Kyu-Sup;Yoon, Gil-Sang
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.12 no.3
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    • pp.1051-1057
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    • 2011
  • By the recently developed GMP(Glass Molding Press) process, aspheric glass lenses are widely used in many optical applications such as digital cameras, optical data storages and electrical devices etc. The GMP process can economically produce complex shaped glass lenses with high precision and good repeatability. This study deals the optimization of molding conditions for aspheric glass lenses in progressive GMP process through Design Of Experiment(Taguchi method). Tree main factors for molding conditions were selected based on pressure, temperature and cooling time at 1st cooling stage. From the analysis of experiments which were preformed with 3-cavity glass mold, it was revealed that the cooling time was the most sensitive parameter for form accuracy(PV) in progressive GMP process.

An automated CAD System of Product with Bending Constraints and Piercing for Progressive Working (구속을 갖는 굽힘 및 피어싱용 제품의 프로그레시브 가공을 위한 자동화된 CAD 시스템)

  • Choe, Jae-Chan;Kim, Chul
    • Journal of the Korean Society for Precision Engineering
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    • v.16 no.11
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    • pp.174-182
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    • 1999
  • This paper describes a research work of developing a computer-aided design of product with bending constraints and piercing for progressive working. an approach to the CAD system is based on the knowledge-based rules. Knowledge for the CAD system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written AutoLISP on the AutoCAD with a personal computer and is composed of four main modules, which are input and shape treatment, flat pattern layout, production feasibility check, and strip-layout module. Based on knowledge-based rules, the system is designed by considering several factors, such as radius and angle of bend, material and thickness of product, complexities of blank geometry and punch profile, bending sequence, availability of press. Strip layout drawing generated by piercing with punch profiles divide into automatically for external area is shown into graphic forms, including bending sequences for the product with piercing and bending constraints. Results obtained using the modules enable the designer and manufacturer of piercing and bending dies to be more efficient in this field.

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Korean fine blanking industries and technology development (국내 파인블랭킹 산업 현황과 기술 개발)

  • Kim, Jong-Deok
    • Design & Manufacturing
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    • v.9 no.1
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    • pp.5-8
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    • 2015
  • The company Daewoo Precision Industries imported fine blanking press of 40 tons from Switzerland with fine blanking tool in order to produce the fuse part of bomb in 1978 at first in Korea. About 1985 the first fine blanking tool for producing the door lock parts was manufactured in the company Gold Star (now LG). And then this technology was grown up with the growth of automobile industries in Korea. Now 31 companies are closely related to the fine blanking technology and there are total 146 fine blanking presses in Korea. The developments of fine blanking technology in industries have been oriented to the production of precise fine blanking parts, the reduction of die roll height on fine blanking parts, the production of complex fine blanking parts with progressive fine blanking tool including forming and forging technology, the production of high-strength steel fine blanking parts and so on. Some R&D activities in KITECH were introduced.

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Rigid-Plastic Finite Element Analysis for Forging Process Design of a Hollow Flange

  • Bae, Sung-Woo;Kim, Yohng-Jo
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.3 no.1
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    • pp.59-65
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    • 2004
  • Hollow flange-shaped parts rue widely used in transportation systems. For good quality products, in general, design of preforms and die shapes for a progressive forging process is an important issue. For the design of die shapes for the forging process of a hollow flange, computer simulations Were earned out using the rigid-plastic finite element method. Forging defects like folding were seen in the vicinity of die corners at the typical shape ratios of upper and lower dies Die shape ratios at which the forging defect could occur during the extrusion-forging process of the hollow flange were investigated. The results might be efficiently used for the proper design of perform shapes, die shapes, and forging processes.

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Analysis of a Process Sequence in Precision Press Forming of Electronic Components (정밀전자부품 성형을 위한 소성가공 공정해석)

  • 변상규;허병우;강범수
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1995.10a
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    • pp.119-127
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    • 1995
  • A process sequence in precison press forming of electronic components is investigated by the finite element method. Aperture, a key component of electronic gun, is formed through a wequence of about 15 operations, among which the beading & bending, the first coining, and the second coining operations are expected to be most critical in view of industrial experts' opinions. Thus, the analysis performed by a commercial code MARC focuses on the three operations, and comparisons are made between the results of the analysis and the measurement of experimental forming of the component, and it appears a sound agreement.

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