• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.206-209
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• 2004

In the hydroforming process the number of process can be reduced by combining pre-forming process and post-forming process such as the bending, piercing and the embedding process. Integrated studies on the embedding manufacturing technology have been performed by analyzing the deformed mode of the tubes and the optimal process parameters. In this study, a simulation model that can prove clamping force between the clamping element and tube has been investigated by FEM. The characteristics of the embedded parts, such as the shape of the screw tip, screw thread and shape of thread were investigated at various clamping element conditions.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.4
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• pp.14-20
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• 1998

This paper describes a computer-aided die design system of progressive die for making CPT grid. An approach to the development of the automatic design system is based on knowledge-based rules. The developed system is designed by considering several factors, such as grid geometry and punch profile. Grid, a key component of electronic gun, is formed through a sequence of many operations, among which the pilot piercing, beading, notching, bending, swaging and slotting etc. Using the developed system, design parameters are determined and output is generated in graphic forms. Therefore the developed system provides part drawing and the assembly drawing of die set.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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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.

• Transactions of Materials Processing
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• v.14 no.9 s.81
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• pp.756-763
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• 2005

The applicability and productivity of hydroforming process can be increased by combining pre- and post-forming processes such as the bending, piercing and embedding process. For the fabrication of automotive parts, the hollow bodies with connecting nuts are widely used to connect parts together. Hollow body with connecting nuts has been conventionally fabricated by welding nuts or screwing in autobody screws. It requires multiple steps and devices fur the welding and/or screwing Therefore in this study, hydro-embedding process that combines the hydraulic embedding of connecting element(nut) with hydroforming process is investigated. Studies on the hydro-embedding technology have been performed to optimize the shape of the connecting element by analyzing the deformed mode of the embedded tube The effects of the shape of the screw tip, screw thread and shape of thread on the connection force between the tube and the connecting element have been investigated to optimize the shape of connecting element. Finite element analysis has also been performed to provide deformation behaviors of the tube surrounding a hole produced by hydro-embedding.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.3
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• pp.49-55
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• 2017

Most motor cases adopt deep drawing products, which are excellent in waterproof functions, concentricity, right angle, and quality. In addition, the blower motor and seat motor, which are installed in the car interior and do not require waterproof function, adopts a multi-forming manufacturing method. The deep drawing process requires an expensive transfer press that can digest approximately 12 processes, such as drawing, trimming and piercing. On the other hand, products can be produced with low investment because the multi-forming method is composed of one multi-forming machine or one multi-forming machine and one press. The multi-forming machine is a high-priced facility that is mostly imported and a bending / shearing process multi-foaming machine, which was developed by domestic small and medium-sized enterprises, is not enough to reduce the production cost. An integral multi - forming machine is used as a limited working method for thin material and small products. A large product and thick material has a high shear load. A large product and thick material has a high shear load and uses a single crank press. After blanking, the worker manually feeds the material to a multi-forming machine. When the bending operation is performed in the multi-forming machine, it is transferred to the press again to calibrate the dimensions. This variance in work processes has resulted in lower cost competitiveness due to the lower productivity, quality issues, and excessive operator input. The aim of this study was to establish a stable and cost - effective production system through bending / shearing process separation and facility automation.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.2
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• pp.450-455
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• 2017

A shield connector is an automotive electrical component that is used to connect electrical wiring in a vehicle. This part is made by progressive pressing using a phosphor bronze material with high electrical conductivity. The shape of the product is not complicated, but plastic forming techniques are required, such as deep drawing and bending, as well as shearing techniques such as piercing and notching. The finite element method was used to model the process. The strip layout design stage of the progressive die makes it possible to examine the thickness change, the stability of the forming process, and the spring-back. As a result of this analysis, it is possible to predict the correction values for the tendency of cracks, wrinkles, and incomplete plastic deformation, and to identify possible problems in advance. As a countermeasure against the forming error caused by the drawing process analysis, the drawing shape was modified and applied in the process design. For effective material utilization, a 3D strip layout was designed using an optimized blank shape based on nesting. The results improve the crack stability and spring-back of shield connector products produced through progressive pressing.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.10
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• pp.6977-6984
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• 2015

It is faced with the necessity of multi roll forming process of the ball slide rail which is made by adding the separate manufacturing processes, piercing, bending, trimming, to the roll forming process of a continuous plastic deformation, to improve the quality. However, the vibration and noise of the press machine in this process leads to the quality degradation of slide rail manufactured in this process. In this study, the roll was designed considering the optimal strain rates by the roll forming program with finite element method. And to estimate the static stability of the multi process the Von-Mises stress and deformation on the press was calculated with a structural analysis program. Also, to avoid driving systems in the resonance region their natural frequencies in the 1st and 2nd mode were calculated through the modal analysis. To verify its dynamic stability improvement the magnitudes of noise and vibration in the existing and studied system were compared using a microphone and accelerometers. And the widths and surface roughnesses of the rails which had been produced in the existing and studied process were measured. Therefore, it is known that multi roll forming process is stable in the analytical and experimental study.