• Transactions of Materials Processing
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• v.24 no.6
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• pp.400-404
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• 2015

For mass production of stamped parts, which require complicated in-press operations, it is always advisable to use a progressive die set. It is difficult to choose a progressive die set if the stamped parts need to be deep drawn and especially if they are unsymmetrical. Because unsymmetrical deep drawing parts are very sensitive to the effect of weight during moving to the next step, they are hard to exactly locate on the die face. An automotive seat side cushion panel is about 80mm high, unsymmetrical and its low edge needs hemming, so it is hard to produce even using a progressive die set. In the current paper a progressive stamping for seat side cushion panel was examined. Five strip bridges were considered to be strong enough to move to the next die as predicted by the CAE analysis.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.10
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• pp.2211-2218
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• 2002

In this study, an optimal design study has been made to determine dimensions of die and multi stress rings for extrusion process. For this purpose, a thermo-rigid-viscoplastic finite element program, CAMPform, was used fur forming analysis of extrusion process and a developed elastic finite element program fur elastic stress analysis of the die set including stress rings. And an optimization program, DOT, was employed for the optimization analysis. From this investigation, it was found out that the amount of shrink fitting incurred by the order of assembly of the die set should be taken into account for optimization when the multi stress rings are used in practice. In addition, it is construed that the proposed design method can be beneficial fur improving the tool life of cold extrusion die set.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.355-362
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• 2002

In this study, an axi-symmetric finite element program for elastic analysis of the die set shrink fitted in cold extrusion was developed. The geometrical constraint according to shrink fit was enforced by employing the Lagrange multiplier method. The numerical results for strain and stress distributions in the die set including single and multi stress rings assembled by shrink fit were compared well with the Lame's equation for thick-walled solution available in the literature. To extend the applicability of the analysis program developed, various cases without or with stress ring and with pre-stress applied on stress ring were numerically investigated as well. This numerical approach enables the optimization study to determine optimal dimensions of die set to improve tool life for practical use in industry.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.03a
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• pp.71-77
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• 1995

In this paper, an experimental study of hot forging process is carried out using plasticine. In order to manufacture the die set, Stere olithography Apparatus(SLA) which is most widely used rapid prototyping system is introduced. Turbine blade forging is executed using plasticine and the SLA prototype die set. Through the experiment ,it turned out that SLA prototype is suitable to the die set for the plasticine workpiece, and theformability and forming load of turbine blade forging are predicted.

• Transactions of Materials Processing
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• v.31 no.1
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• pp.5-10
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• 2022

In multi-stage cold forging process, to enhance the productivity and product quality, in-site process monitoring technique by implanting sensors such as piezo-sensor and acoustic emission sensor has been continuously studied. For accurate analysis of the process, the selection of appropriate sensors and implantation positions are very important. Until now, in a multi-state forging machine, wedge parts located at the end of punch-set are used but it is difficult to analyze minute changes in die block-set. In this study, we also implanted sensors to the die part (die spacer) and compared signals from both sensors and found that sensing signals from die part showed enhanced process monitoring results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.382-386
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• 2009

This paper describes design and analysis techniques of cold forging process for precise producing of T-200 type spider made of SCr420H by utilizing pneumatically operated enclosed die set. Since deducing feasible closing force is an important factor to optimize entire pneumatically operated cold forging system, a series of FE analyses with varying the number of gas cylinders has been carried out to investigate the influence of closing force upon the direction of applied load at die surfaces. It also reveals the optimum distribution of the gas cylinders in terms of the flatness of upper/lower plates.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.198-201
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• 2003

The multi-action forging process is one of developing directions of forging technologies. In this study, the multi-action die is designed and developed by the screws mechanism and the forging simulation is conducted by using plasticine to investigate the optimum conditions for the design of the screws. The results show the design variables are optimum when the diameter is 30 mm and the screw angle is $60^{\circ}$ for the upper screw rod and the outer diameter is 60 mm and the screw angle is $23.4^{\circ}$ for the lower screw tube. It makes the relative velocity between the upper punch and the die to be two to one, which is the expected condition. The material flow of the plasticine forgings is uniform. Therefore, it is feasible to use the screw set as the multi-action mechanism for controlling the movement of the multi-action forging die set.

• Design & Manufacturing
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• v.17 no.4
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• pp.63-71
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• 2023

In order to increase the extrusion production speed of aluminum, extrusion die cooling technology using liquid nitrogen has recently attracted a lot of attention. Increasing the extrusion speed increases the temperature of the bearing area of extrusion dies and the extrusion profile, which may cause defects on the surface of extruded profile. Extrusion die cooling technology is to directly inject liquid nitrogen through a cooling channel formed between the die and the backer inside the die-set. The liquid nitrogen removes heat from the die-set, and gaseous nitrogen at the exit of the channel, covers the extrusion profile of an inert atmosphere reducing the oxidation and the profile temperature. The aim of this study is to evaluate the cooling capacity by applying die cooling to extrusion of Al-Mn-based aluminum alloy flat tubes, and to investigate the effects of die cooling on the change in extrusion characteristics of flat tubes. Cooling capacity was confirmed by observing the temperature change of the extrusion profile depending on whether or not die cooling is applied. To observe changes in material characteristics due to die cooling, surface observation is conducted and microstructure and precipitate analysis are performed by FE-SEM on the surface and longitudinal cross section of the extruded flat tubes.

• Transactions of Materials Processing
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• v.16 no.6
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• pp.479-487
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• 2007

Die life is generally estimated taking failure life and wear amount into consideration. In this study, the forging die life was investigated considering both of these two factors. The fatigue life prediction for the die was performed using the stress-life method, i.e. Goodman's and Gerber's equations. The Archard's wear model was used in the wear life simulation. These die life prediction techniques were applied to the die used in the forging process of the socket ball joint of a transportation system. A rigid-plastic finite element analysis for the die forging process of the socket ball was carried out and also the elastic stress analysis for the die set was performed in order to get basic data for the die fatigue life prediction. The wear volume of the die was measured using a 3-dimensional measurement apparatus. The simulation results were relatively in good agreement with the experimental measurements.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.4
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• pp.423-430
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• 2010

Hot closed-forging process and the die used for forming an automotive flange were analyzed from the viewpoints of heat transfer, grain-flow lines, and stresses to obtain a forged product without defects such as surface cracks, laps, cold shots, and partial filling. The forging process including up-set, pre-forging, final forging and pressing forces was investigated using finite element analysis. The influence of the preform die and the ratio of the heights of the upper die to lower die on the forging process and die were investigated and a die shape ($10^{\circ}$ for the preform die, and 1.5:1 ratio for the final die) suitable to achieve successful forging was determined on the basis of a parametric study. All parametric design requirements such as strength, full filling, and a load limit of 13,000 KN were satisfied for this newly developed flange die. New dies and flanges were fabricated and investigated. Defects such as partial filling and surface cracks were not observed.