• Journal of the Korean Society for Precision Engineering
• /
• v.32 no.11
• /
• pp.977-982
• /
• 2015

This study uses finite element analysis to evaluate the forming load of tool entrance angle of the cold forward extrusion molding process of helical gear; this can replace the spur gear applied to the Electronic Parking Brake (EPB) system. A cold forging process is often used in the automobile industry as well as in various industrial machines due to its high efficiency. Finite element analysis is frequently used when interpreting results of the forging process. Formality was evaluated by calculating tooth profile filling rate of helical gear. Change in required forming load was investigated when the entrance angle of forward extrusion tool die was changed from $30^{\circ}$ to $60^{\circ}$, also by finite element analysis. We suggest suitable tool entrance angles.

• Transactions of Materials Processing
• /
• v.28 no.4
• /
• pp.212-218
• /
• 2019

In this study, the first drawing die for the production of coil wedge is redesigned in order to enhance properties such as dimensional accuracy, dimensional uniformity, non-magnetism, and residual stress. The equivalent strain distribution is observed to be asymmetric at certain corners of the product and un-filling of material is also observed at the same location, based on the results of FEM simulation for the current drawing process. Additionally, a relatively huge amount of deformation is concentrated on the surface of the reference product leading to an increase in magnetic component and surface residual stress. After re-designing the cross-section of the first drawing step process conformed to relatively higher amount of reduction ratio, reduction of both surface residual stress and the volume fraction of magnetic component could be achieved for the finally-drawn coil wedge product.

• Journal of the Korean Society for Precision Engineering
• /
• v.12 no.3
• /
• pp.42-52
• /
• 1995

An UBET(Upper Bound Elemental Techniquel) program has been developed to analyze forging load, die-cavity filling and effective strain distribution for flashless non-axisymmetric forging. To analyze the process easily, it is suggested that the deforma- tion is divided into two different parts. Those are axisymmetric part in corner and plane- strain part in lateral. The total power consumption is minimized through combination of two deformation parts by building block method, form which the upper-bound forging load, the flow pattern, the grid pattern, the velocity distribution and the effective strain are deter- mined. To show the merit of flashless forging, the results of flashless and flash-forging processes are compared through theory and experiment. Experiments have been carried out with plasticine billets at room temperature. The theoretical predictions of the forging load and the flow pattern are in good agrement with the experimental results.

• Design & Manufacturing
• /
• v.16 no.2
• /
• pp.46-52
• /
• 2022

As the consumer market in the eco-friendly vehicle industry grows, the demand for water pump in a electric car parts market. This study intend to propose a mathematical model that can verify the effect of improving thermal properties when a non-conductive cooling filler liquid is introduced into an electric vehicle water pump. Also, the pros and cons of the immersion cooling method and future development way were suggested by analyzing the cooling characteristics using on the derived analysis solution. Thermal characteristics analysis of electric water pump applied with non-conductive filler liquid was carried out, and the diffusion boundary condition in the motor body and the boundary condition the inside pump were expressed as a geometric model. As a result of analyzing the temperature change for the heat source of the natural convection method and the heat conduction method, the natural convection method has difficulty in dissipating heat because no decrease in temperature due to heat release was found even after 300 sec. Also, it can be seen that the heat dissipation effect was obtained even though the non-conductive filling liquid was applied at the 120 sec and 180 sec in the heat conduction method. It has proposed to minimize thermal embrittlement and lower motor torque by injecting a non-conductive filler liquid into the motor body and designing a partition wall thickness of 2.5 mm or less.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.25 no.9
• /
• pp.1438-1443
• /
• 2001

The significance of the casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to reduce press capacity and material cost. Firstly, a hot compression test was performed with cast cylindrical billets in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from 420$\^{C}$ to 450$\^{C}$. The suitable strain rate was 1.5 sec(sup)-1. The deformation amount of a preform of a preform in a forging process is a key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of case preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeded 0.7. From the result of FE analysis, optimal configurations of the cast preform and the die were designed for a large flange. The filling and solidification analysis for a sound cast-preform was carried out with MAGMA soft. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Korean Journal of Food Science and Technology
• /
• v.27 no.3
• /
• pp.404-413
• /
• 1995

System parameters (extrusion temperature, extrusion pressure, specific mechanical energy, mean residence time) were analysed on three different screw configurations during twin-screw extrusion of wheat bran. Experiments were conducted over a screw speed of $280{\sim}380\;rpm$, feed rate of $22{\sim}38\;kg/hr$ and moisture content of $17{\sim}33%$ using screws assembled with 3, 4, and 5 reverse screw elements (RSE) adjacent to the heating zone of the barrel. Extrusion temperature increased with increasing RSE but it decreased with increasing feed rate and moisture content. Decreasing the filling ratio of the screw resulted in a lower extrusion pressure, and increasing the length of the RSE gave similar results due to the higher temperature and lower viscosity of melted dough. It was also observed that increasing the feed rate and decreasing moisture content resulted in the reduced extrusion pressure. Specific mechanical energy (SME) decreased when the feed rate and moisture content increased, and SME increased when using RSE posses from 3 to 5. Screw configuration posses with 4 RSE yielded the longest RT, and the smaller the die hole, the higher the RT. In contrast, RT decreased when the feed rate increased. With increasing moisture content RT for 3 RSE increased, but that for 4 and 5 RSE decreased.

• Design & Manufacturing
• /
• v.17 no.3
• /
• pp.8-14
• /
• 2023

In this study, basic research was conducted on manufacturing technology of thick-walled light guide a component that controls the light source of automobile lamps. As a preliminary study for manufacturing the final injection molded parts, a model for analyzing the influence of micro patterns on light guides is presented. The optical characteristics of the light guide were analyzed according to the change of the curvature radius of the micro-optical pattern, and the injection molding characteristics of the light guide according to the change of injection molding conditions were analytically evaluated. It was confirmed that the luminance uniformity improves as the R value decreases for changes in the micro-pattern R value, but it was confirmed that there are technical limitations in actual injection mold core processing and high-replication injection molding. Injection molding analysis showed that cooling channel design is very important compared to general injection molding due to thick-wall characteristics and thickness variation. It was also confirmed that the cooling channel has a great influence on the cycle time and birefringence result due to residual stress. As a result of analyzing the influence of filling time, holding condition, and cooling on shrinkage, it was found that the cooling water temperature has a significant effect on the shrinkage of ultra-fine light guide parts, and the holding condition also has a significant effect.