• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2006년도 춘계학술대회 논문집
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• pp.341-344
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• 2006

Finite element analysis and verification experiments were performed in order to find cause of defects such as folding and improper radius around the root area of the thread rolled stud bolts. Thread rolling experiments under several conditions were also carried out to understand the effect of process parameters, such as the rotation speed of the dies and the hardness of the work pieces, on the product quality. Folding defects at the top of thread are attributed to the higher hardness of the work piece and higher rotation speed of the rolling die. It was also found that the radius of screw mainly determined by the radius of the die.

• Design & Manufacturing
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• 제2권4호
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• pp.16-23
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• 2008

This paper describes $R_p,\;R_d,\;R_c,\;R_{cp},\;R_{cd}$ for design and manufacture of die by comparing the results. Results of this study could be reduced from three processes to two processes and drawing can be conducted using one die set by modifying structure of the punch head and die plate. Oil canning phenomenon can be prevented when circle blanking or ellipse blanking in blanking drawing. $R_c$, the important factor of drawing process was able to evaluate properly in designing of product.

• 한국기계기술학회지
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• 제20권6호
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• pp.924-928
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• 2018

The objective of this study is to solve a problem that is occurred during the spline machining of tubular shaft yoke in both side IMS module. In order to simulate the problem, the movement direction of upper die was set as standard case and error case. The material of tubular shaft yoke was set to S20C as refer to the analysis library. The movement directions of upper die were separated with standard case and error case. The error case was set to simulate the problem in the spline machining of tubular shaft yoke. In order to solve the problem, the outer radius of upper die were modelled from 9.40mm to 9.44mm. The simulation results were analyzed and compared in terms of effective stress, metal flow line and folding phenomena characteristics. In case of the outer radius of upper die was 9.42mm, it was observed a relatively uniform effective stress distribution and had a straight metal flow line.

• Design & Manufacturing
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• 제13권3호
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• pp.19-23
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• 2019

In the mold industry, CAM software has been introduced to solve the impossible or time-consuming part of the mold industry because the increase in labor costs, the drop in mold price, and the short delivery time are tasks to be solved not only in the manufacturing industry but also in the mold industry as a whole. In order to reduce the processing time and improve the surface roughness, we have been conducting various researches for efficient machining. This study was carried out to compare the ball end mill and radius end mill tools with the Power mill software and NC brain software under the same conditions and to find out the most efficient method of machining the smooth drafting surface and improving the surface roughness. (1) By machining the smooth drafting surface using radius end mill, the machining time is 23.7% faster than when using ball end mill. (2) Surface roughness when machined with radius end mill is smoother than when using ball end mill. Based on these results, it can not be applied to all shapes, but if it is a relatively wide and simple gradient shape, the raster machining method using radius end mill can be more effective in terms of delivery and quality than machining with ball end mill.

• 한국정밀공학회지
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• 제16권7호
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• pp.24-31
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• 1999

Bulging is a forming method to shape of die cavity by using hydraulic pressure in tube or vessel. Bulging machine and die were developed in order to produce vessel for keeping warm. Bulging machine is a double type with two horizontal cylinders for bulging of two pieces at the same time. The developed die system has one bulging die and two drawing dies for necking at the both ends of tube. The diameter of tube expands by hydraulic pressure in tube. at the same time, thrust at the both ends of tube. pushes tube in the direction of expansion to obtain high expanding rate with no crack. In this study, the bulging properties were investigated to solve tube crack and necking in manufacturing vessel by the combination method of bulging and drawing. As a result, high expanding rate of tube radius without crack, precision necking and high productivity were obtained.

• International Journal of Precision Engineering and Manufacturing
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• 제2권4호
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• pp.40-46
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• 2001

Bulging is a forming method to shape die cavity by using hydraulic pressure in tube or vessel. Bulging machine and die were developed in order to produce vessel for keeping warm. Bulging machine is a double type with two horizontal cylinders for bulging of two pieces at the same time. The developed die system has one bulging die and two drawing dies for necking at both ends of the tube. The diameter of tube expands by hydraulic pressure in tube. At the same time, thrust at both ends of the tube pushes tube in the direction of expansion to obtain high expansion rate with no crack. In this study, the bulging properties were investigated to solve tube crack and necking in manufacturing vessel by combining bulging and drawing. As a result, high expanding rate of tube radius without crack, precision necking and high productivity were obtained.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1998년도 춘계학술대회논문집
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• pp.254-257
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• 1998

The twisting and the bending of extruded product are caused by the shapes of products and by the shapes of die surfaces and by the shapes of die land. Because the elliptical shape and the circular shape of the extruded product have the symmetry line of cross-section area, the twisting and the bending of product has not occurred. But the analysis by the DEFORM-3DTM show that the twisting and the bending of extruded product can be occurred by the twisting of the twisting of the die land and by the curving of the die land. The results by the analysis show that the twisting angle of the extruded procduct increases by the twisting angle of the die land and the curvature of the extruded products increases by the radius of bending of the die land.

• 한국결정성장학회지
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• 제33권6호
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• pp.216-225
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• 2023

본 연구에서는 냉간 헤딩 공정에서 성형하중과 펀치 금형의 마모 감소를 통한 펀치 수명 증대를 위해 헤딩용 펀치 형상 최적설계를 수행하였다. 기존 생산에 사용되는 냉간 헤딩 펀치와 성형공정에 대한 유한요소해석 시뮬레이션을 통해 성형하중과 유동 특성 분석, 펀치금형에 집중되는 유효응력 및 마모량에 대하여 분석하였으며, 이를 통해 금형 마모와 밀접한 주요 설계인자를 확인하였다. 펀치금형의 최적설계 변수로서는 펀치 금형 포인트각(Point angle), 에지 반경값(Corner radius), 펀치소재재종(die material type), 마찰계수(friction coefficient) 등의 4가지 변수를 대상으로 4인자 3수준 인자 및 변수 수준을 설정하고, 성형해석 시뮬레이션과 다구찌법을 활용하여 설계인자별 영향도를 분석하여 최적의 최적설계 인자를 결정하였다. 본 연구를 통해 얻어진 최적설계변수를 적용하여 냉간 헤딩용 펀치 최적설계 시뮬레이션 결과, 각 펀치에 발생하는 최대유효응력은 최대 8.9 % 감소 효과를, 최대 펀치 마모 깊이는 37 % 감소 효과를, 성형하중은 평균 20% 수준 의 감소효과를 얻을 수 있었다. 현재, 소성 성형제품군이 적용되는 자동차, 건설 플랜트사에서 요구되는 고품질에 대응하면서도 적정 제조원가 절감을 위한 성형성 개선을 위한 성형공정개발 및 금형설계의 최적화가 지속적으로 필요하며, 향후 연구 결과를 현업에 적용하여 제품 성형성 개선 및 금형수명 증대 관리를 위한 기술자료로 활용하고자 한다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.370-373
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• 2008

It is known that the temperatures of die, punch, holder and punch pad need to be kept different to get better formability in Mg sheet forming processes. Heating and cooling channels are usually equipped in each tool to assign different temperature. This study focused on the optimal design of the heating and cooling channels for a cross-shaped deep drawing die set. While the die and blankholder were heated to and kept at $250^{\circ}C$ by using heat cartridges, the punch and punch pad were kept at much lower temperature than that of the die and blankholder by water circulating through cooling channels. All the approaches were done by numerical analyses, aiming to maximize the cup height and to minimize the punch corner radius without any failure.

• 한국정밀공학회지
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• 제13권9호
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• pp.156-164
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• 1996

Tool interference is one of the most critical problems in machining die cavities and punches. When machining concave or convex regions of cavities with large radius tool in rough cutting, the tool easily overcuts or undercuts the portions of the surface, which result in machining inaccuracy. So the generation of interference-free tool path must be required for more efficient rough cutting. In this paper, we present a method for modeling die cavities which consist of simple surface or analytic compoyund surfaces and present an algorithm for checking and removing the tool interference occurred in machining the die cavities. Using these algorithms, we can represent a die cavity, and check the interfer- ence regions, and then remove these interferences. Especially we focus on the side interference in the sides of analytic elements and base surface boundary.