• 한국정밀공학회지
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• 제22권9호
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• pp.137-146
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• 2005

This paper describes a research work to develop a computer-aided design for the product made by progressive working of bending and piercing. An approach to the system for progressive working is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer and is composed of three main modules, which are input and shape treatment, flat pattern layout, strip layout modules. The system is designed by considering several factors, such as piercing and bending sequences by fuzzy set theory, complexities of blank geometry, punch profiles, and the availability of a press equipment. Strip layout drawing generated in the strip layout module is presented in 3-D graphic forms, including piercing and bending sequences with punch profiles divided into for external area. Results obtained using the modules enable the manufacturer for progressive working of electric products to be more efficient in this field.

• 한국정밀공학회지
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• 제14권7호
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• pp.39-48
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• 1997

This paper describes the process planning system of a computer-aided design of blanking and piercing for irregularly shaped sheet metal products. An approach to the system is based on knowledge-based rules. The process planning system is designed by considering several factors, such as the complexity of blank geometry, production feasibility of products, and punch profile complexity. Therefore this system which was implemented production feasibility check and strip layout module can carry out a process planning considering a production feasibility area of both internal and external features, a dimension of blanked hole, a coner and a fillet radius for irregualrly shaped sheet metal products and generate the strip layout in graphic froms. Knowledges for process planning are extracted from plasticity theories, handbooks, relevant references and empirical know- hows of experts in blanking companies. This provides powerful capabilities for process planning system of irregularly shaped sheet metal products.

• 한국산학기술학회논문지
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• 제20권9호
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• pp.517-524
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• 2019

오버드라이버 허브클러치는 자동차 6단 자동 변속기 미션에 장착되어 엔진의 여유출력을 이용해 연료사용을 절감시켜주는 부품이다. 본 연구에서는 오버드라이버 허브클러치 제품에 대해 피어싱 공정 중 펀치에 가해지는 하중 및 소재 처짐량을 최소화 하고자 한다. 공정 중 펀치의 하중과 처짐량에 영향을 줄 수 있는 다이 클리어런스(die clearance)와 전단각도(shear angle) 그리고 마찰계수(friction coefficient)를 설계 변수로 설정했다. 또한 펀치의 하중과 소재 처짐량에 대해 각 설계 변수들의 영향도를 확인하기 위해 민감도 분석(sensitivity analysis)을 진행했다. 그 결과 전단 각도, 마찰 계수, 다이 클리어런스 순으로 하중 및 처짐량에 대해 민감한 것으로 조사되었다. 이를 통해 펀치의 하중과 소재 처짐량을 목적함수로 설정하고, 반응표면법(Response Surface Method)을 통해 각 설계 변수들과 목적함수의 방정식을 도출했다. 이를 통해 설정된 설계 변수들의 최적 값을 도출해 유한요소해석에 적용한 결과 펀치의 하중 및 소재의 처짐량이 기존대비 22.14% 개선됐다.

• 한국산학기술학회논문지
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• 제18권2호
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• pp.450-455
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• 2017

쉴드 커넥터는 자동차 전장부품으로 차량 내 전기 배선을 연결하는데 사용된다. 이 부품은 전기 전도도가 높은 인청동 재질을 사용하고 프로그레시브 프레스 성형으로 제작된다. 본 제품 형상의 기하학적인 측면을 고려했을 때 복잡하지 않지만, 드로잉, 밴딩 등의 소성가공과 피어싱, 노칭 등의 전단 가공을 실시하여 제품 성형을 완성해야 한다. 프로그레시브 금형을 설계하는 과정 중에 공정 및 스트립레이아웃 설계단계의 성형 해석 모듈을 활용하여 제품의 재질에 따른 두께 변화 및 성형 안전성, 스프링 백 (Spring Back) 검토를 수행하여, 균열 혹은 주름의 경향과 불완전 소성 변형에 대한 보정치를 예측 및 발생 가능한 문제들을 사전에 확인하고, 드로잉 공정 초기에 발생된 성형 불량에 대한 대책으로 드로잉 형상을 수정하여 공정 설계에 반영하였다. 공정설계에서 얻어진 제품의 블랭크 전개 형상은 효과적인 재료 이용을 위해 네스팅에 의한 최적화된 블랭크 배치로 재료의 손실을 최소화하여 3차원 스트립레이아웃 설계를 완성하였다. 본 연구를 통해 프로그레시브 성형을 통해 생산되는 쉴드커넥터 제품의 균열과 스프링백 현상을 사전에 개선하여 생산안정도를 향상시켰다.

• 한국산학기술학회논문지
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• 제16권10호
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• pp.6977-6984
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• 2015

품질 향상을 위해 연속적인 소성 변형을 이용한 롤 포밍 공정에 피어싱, 벤딩, 트리밍 등 별도의 가공공정을 통합한 볼 슬라이드 레일의 멀티 롤 포밍 공정의 필요성이 대두되고 있다. 하지만 프레스기의 진동 및 소음은 이 공정에서 생산되는 슬라이드 레일의 품질 저하를 유발한다. 본 연구에서는 롤 포밍 유한요소 프로그램으로 최적 변형률을 고려하여 롤을 설계하였다. 그리고 멀티 공정의 정적 안정성을 예측하기 위해 구조해석 프로그램으로 프레스기에 대한 응력 및 변형량을 계산하였다. 또한 공진영역에서의 장치들의 운전을 회피하기 위해 Modal 해석을 통해 1, 2차 모드에서의 고유진동수를 계산하였다. 그 결과 공정의 동적 안정성 개선을 확인하기 위해 마이크로폰과 가속도계를 이용하여 기존 및 연구 공정들의 소음, 진동의 크기를 비교하였다. 그리고 기존 및 연구 공정으로 생산되어진 레일의 폭 치수와 표면거칠기를 측정하였다. 따라서 해석 및 실험적 연구를 통해 멀티 롤 포밍 공정이 안정하다는 것을 알 수 있었다.

• 소성∙가공
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• 제7권3호
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• pp.246-259
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• 1998

This paper describes a research work of developing a computer-aided design and manufacturing of irregular shaped sheet metal product for blanking or piercing and bending operations. An approach to the system is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories experimental results and the empirical knowledge of field experts, This system has been written in AutoLISp on the AutoCAD and in customer tool kit on the SmartCAM with a personal computer and is composed of nine modules which are input and shape treatment, flat pattern-layout, pro-processor module. Based on the knowledge-based rules, the system is designed by considering several factors, such as material and thickness of product complexities of blank geometry and punch profile sheet metal to give flat pattern and automatically account for the adjustment of bending allowances to match tooling requirements by checking dimensions and generating NC data automatically according to drawings of die-layout module. Results carried out in each module will provide efficiencies to the designer and the manufacturer of blanking or piercing and bending die in this field.

• 한국기계가공학회지
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• 제1권1호
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• pp.63-70
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• 2002

In the field of design and making tool for press working, the progressive die for very thick sheet metal(SS41, 4mm) is a specific division. In order to prevent the defects, the optimum design of the production part, Strip layout, die design, die making and tryout etc. are necessary. They require analysis of many kinds of important factors, i.e. theory and practice of metal working process and its phenomena, die structure, machining condition for die making, die materials, heat treatment of die component, know-how and so on. In this study, we designed and constructed a progressive die of multi stage and tried out through the I-DEAS, DEFORM, and CAD/CAM application. Out of these processes, the die development could be taken advanced technology. Especially the result of try out and its analysis become to the characteristic of this study.

• 소성∙가공
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• 제21권3호
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• pp.202-206
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• 2012

Marking is a process that engraves letters or a pattern onto the surface of sheet metal. During marking, it is important to set the proper working conditions for clarity of the letters. In this study a simple case for forming circular protrusions by half-piercing and embossing was initially attempted to determine the working conditions which gave good results with respect to shape accuracy. Corner-radius and flatness of circular protrusions made under several experimental conditions were measured and compared. It is shown that the precision of protrusions by half-piercing is superior to that of embossing, and the clearance between punch and die exerts a strong influence on the shape accuracy rather than the penetration percentage into the thickness of the sheet metal. The marking dies for "SNUT" letters, as an example, by applying the above results were manufactured with four different clearances. The working variables for the experiment were clearance and marking depth. For the very shallow depth of 0.1mm the letters were not clearly read. Letters marked under other conditions were easily distinguished with increasing marking depth. It was confirmed that the half-piercing technique with proper values of the working variables gives good quality for the marking of sheet metal.

• 소성∙가공
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• 제22권8호
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• pp.437-441
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• 2013

Recently, the engraving of letters or a pattern on a product surface has received more attention especially in trying to satisfy the customer requirements. Half-piecing is a protrusion forming process that pierces only 40~50% of the material thickness. In the current study, the half-piercing technique for making clear letters by protruding sheet material was selected and studied. The influence of clearance and penetration depth was investigated by measuring the camber and extruded length of a protrusion after experiments. In addition, a numerical analysis was performed for the same working conditions and compared with experimental results. It is shown that, as the clearance increases, the camber of a protrusion increases rapidly and the extruded length decreases slightly. The deformation pattern around the cutting edge during half-piercing changes from an extrusion mode to a shearing mode as the clearance changes from minus to plus values. It is also confirmed that the experimental results show a good agreement with the numerical analyses.

• Design & Manufacturing
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• 제16권3호
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• pp.28-33
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• 2022

The recent increasing application rate of advanced high-strength steel(AHSS) for automotive parts makes it difficult to ensure the durability of forming tools. Significant load and friction generated during the piercing process of AHSS increase the wear rate and the damage degree to dies. These harsh process conditions also yield product failures, such as dimensional inconsistency of pierced holes and insufficient quality of hole's sheared edge. This study analyzed the effect of punch wear on the sheared surface of pierced parts and the forming load during the piercing process. Wear-shaped punches showed approximately 20% higher piercing load than normal-shaped punches, and the rollover ratio of the sheared surface also increased. It is considered that the dull edge of wear-shaped punches does not penetrate directly into the material but shears after tensioning it in a piercing direction. In addition, wear-shaped punches experienced compressive load even after completing the piercing process during the down-stroke and tensile load during the up-stroke. This load variation is related to the smaller diameter piercing holes produced by wear-shaped punches compared to normal-shaped punches. Thus, we demonstrated the predictability of the wear level of dies through a comparative analysis of the piercing load pattern.