• 제목/요약/키워드: 냉간다단단조

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다단 미세 치형 허브기어의 프레스 성형기술개발 (Development of Press Forming Technology for the Multistage Fine Tooth Hub Gear)

  • 김동환;고대철;이상호;변현상;김병민
    • 한국정밀공학회지
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    • 제23권6호
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    • pp.44-51
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    • 2006
  • This paper deals with the aspects of die design for the multistage fine tooth hub gear in the cold forging process. In order to manufacture the cold forged product for the precision hub gear used as the ARD 370 system of bicycle, it examines the influences of different designs on the metal flow through experiments and FE-simulation. To find the combination of design parameters which minimize the damage value, the low gear length, upper gear length and inner diameter as design parameters are considered. An orthogonal fraction factorial experiment is employed to study the influence of each parameter on the objective function or characteristics. The optimal punch shape of fine tooth hub gear is designed using the results of FE-simulation and the artificial neural network. To verify the optimal punch shape, the experiments of the cold forging of the hub gear are executed.

등속조인트용 외륜의 다단 냉간 단조공정에 관한 실험적 연구 (Experimental Study on Multi-Stage Cold Forging for an Outer Race of a CV Joint)

  • 강범수;구태완
    • 소성∙가공
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    • 제23권4호
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    • pp.221-230
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    • 2014
  • This study deals with a series of experimental investigations on multi-stage cold forging of an outer race used for a constant velocity (CV) joint with six inner ball grooves. The multi-stage cold forging, which consists of forward extrusion, upsetting, backward extrusion, and combined sizing-necking including ironing, was used to produce a prototype of the outer race. The cold forging tools such as forging punches and dies required in this multi-stage cold forging were also designed and fabricated. For the combined sizing-necking, especially, the longitudinally six-segmentallized punches were developed to easily eject from the necked inner groove of the outer race with consideration of the operating mechanism. Spheroidized SCr420H billet was used in the experimental study. To verify the suitability of the proposed process, the obtained parts were obtained from each forging operation, and the geometries were compared with the target dimensions. It was confirmed that the outer race with six inner ball grooves was well forged by adopting the proposed multi-stage cold forging, and the dimensional accuracy of the forged outer race matched well with the requirements.

등속조인트용 외륜의 다단 냉간 단조공정을 위한 공정개선 및 유한요소 해석 (Process Modification and Numerical Simulation for an Outer Race of a CV Joint using Multi-Stage Cold Forging)

  • 강범수;구태완
    • 소성∙가공
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    • 제23권4호
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    • pp.211-220
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    • 2014
  • The outer race of a constant velocity (CV) joint having six inner ball grooves has traditionally been manufactured by multi-stage warm forging, which includes forward extrusion, upsetting, backward extrusions, necking, ironing and sizing, and machining. In the current study, a multi-stage cold forging process is examined and an assessment for replacing and modifying the conventional multi-stage warm forging is made. The proposed procedure is simplified to the backward extrusion of the conventional process, and the sizing and necking are combined into a single sizing-necking step. Thus, the forging surface of the six ball grooves can be obtained without additional machining. To verify the suitability of the proposed process, a 3-dimensional numerical simulation on each operation was performed. The forging loads were also predicted. In addition, a structural integrity evaluation for the tools was carried out. Based on the results, it is shown that the dimensional requirements of the outer race can be well met.

다단 미세 치형 허브 기어의 프레스 성형기술개발 (Development of Press Forming Technology for the Multistage Fine Tooth Hub Gear)

  • 김동환;이정민;이상호;변현상;김병민
    • 한국정밀공학회:학술대회논문집
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    • 한국정밀공학회 2005년도 추계학술대회 논문집
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    • pp.769-772
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    • 2005
  • This paper deals with the aspects of die design for the multistage fine tooth hub gear in the cold forging process. In order to manufacture the cold forged product fur the precision hub gear used as the ARD 370 system of bicycle, it examines the influences of different designs on the metal flow through experiments and FE-simulation. To find the combination of design parameters which minimize the damage value, the low gear length, upper gear length and inner diameter as design parameters are considered. An orthogonal fraction factorial experiment is employed to study the influence of each parameter on the objective function or characteristics. The optimal punch shape of fine tooth hub gear is designed using the results of FE-simulation and the artificial neural network. To verify the optimal punch shape, the experiments of the cold forging of the hub gear are executed.

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준축대칭 제품 냉간단조용 전문가시스템 개발 - 다단포머 금형의 수평분할 밀 최적설계 - (Development of Expert System for Cold Forging of Axisymmetric Product - Horizontal Split and Optimal Design of Multi-former Die Set -)

  • 박철우;조천수;김철;김영호;최재찬
    • 한국정밀공학회지
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    • 제21권9호
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    • pp.32-40
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    • 2004
  • This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. The system is composed of four main modules. The process planning and the die design modules consider several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

조향장치용 요크 자동다단 정밀냉간단조 공정에서 발생하는 스프링백의 수치적 및 실험적 검증 (Numerical and Experimental Study on Spring Back in Automatic Multi-Stage Precision Cold Forging Process of a Steering Yoke)

  • 김광민;김민철;황태민;정석환;정완진;전만수
    • 소성∙가공
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    • 제28권3호
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    • pp.115-122
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    • 2019
  • In this paper, finite element analysis of an automatic five-stage precision cold forging process of a yoke, a steering part of a passenger's car, is conducted with emphasis on spring back analysis at the yoke-forming stage and its experimental verification is subsequently made. An elastoplastic finite element method with MINI-element technique employed for the analysis of the entire process is explained. There is emphasis that the thin film of material formed between the punch and die in the stage may result to some errors especially in elastoplastic finite element analysis of spring back due to frequent remeshing. The numerical robustness of the spring back analysis in regards to remeshing is hence shown first through investigation into its effect on the predicted spring back. Experimental measurement of displacement due to spring back is carried out for comparison with the predicted results, and they are in a qualitative agreement with each other.