• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.298-301
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• 2009

In this study, the casting process using forged insert was investigated to characterize the manufacturing process by which good mechanical properties can be obtained when compared with existing casting products. Process analysis for the casting design was performed by using FVM (Finite Volume Method) software. In filling process, three kinds of candidate gating systems are considered and analyzed respectively. The molten metal behavior in gating system is so important that it affects the solidification behavior of the cast.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.377-380
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• 2000

The dimensional accuracy of the cold forged part is depended on the elastic characteristics of the die. To obtain the high stiffness of the prestressed die, the first stress ring of the tungsten carbide material is considered. For the design, Lam 's equation is used. The design of the prestressed die has been compared with the conventional that. For the comparison, the FE-analysis using ANSYS has been performed. The results indicate that the prestressed die with the high stiffness can be obtained by the using the high stiffness material as the first stress ring.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.185-190
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• 2000

Die design by computer simulation has some advantages compared with the conventional method which has performed by designer's experiences and trials and errors. The die filling and solidification process of thixoforming process were simulated by MAGMAsoft/thixo module. First of all, thixoforming die design was applied to previously geometry shape. The value of pressure distribution shows high and uniform as the gate diameter is 18mm. Designed gating system considering the deformation of die and product was suggested by the filling simulation. Gate velocity(7.25m/s) of designed gating system shows that propriety to semi-solid metal working process and CAE results were in good agreement with experimental results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.983-987
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• 2001

This paper deals with an automated computer-aided process planning system by which designer can determine operation sequences even if they have little experience in process planning of wheel bolt products by a multi-stage former. The approach to the system is based on knowledge-based rules and a process knowledge base consisting of design rules is built. Knowledge for the system is formulated from plasticity theories, empirical results and the empirical knowledge of field experts. Programs for the system have been written in AutoLISP for the AutoCAD using a personal computer and are composed of two main modules. An attempt is made to link programs incorporationg a number of expert design rules to form a useful package. Results obtained using the modules enable the designer and manufacturer of wheel bolt product to be more efficient in this field.

• Transactions of Materials Processing
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• v.8 no.5
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• pp.437-448
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• 1999

The reheating of the billet in the semi-solid state as quickly and homogeneously as possible is one of the most imposrtant parts. To obtain a fine globular microstructure in cross section of billet, the optimal design of the induction coil for variation of alloys and specimen sizes is necessary. For the thixo-forging process the construction of the reheating data base is very important, because the reheating conditions are different for variation of SSM and billet sizes. So in this study, the optimal coil design of A356 (ALTHIX) and Aι2024 with d×ι=60×90 (mm) to obtain the globular microstructure is theoretically proposed. The suitability of an optimal coil design will be demonstrated by reheating experiments. Finally, the thixoformability of an arbitrarily shaped product is evaluated by its forming variables. The defects and mechanical properties are also investigated.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.12
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• pp.145-151
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• 2001

The dimensional accuracy of the cold forged part is depended on the elastic characteristics of the die. To increase the stiffness of the prestressed die, the first stress ring of the tungsten carbide alloy (WC) is considered. For the design, Lame's equation is used. Diameter ratios and interferences have been determinated by maximum inner pressure without yielding of materials. The design of the prestressed die has been compared with the conventional one. For the comparison, the FE-analysis using ANSYS has been performed. The results indicate that the prestressed die with the high stiffness can be obtained by the using the high stiffness material as the first stress ring.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.13 no.11
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• pp.4950-4955
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• 2012

A bolt manufacturing process is completed with continuous forging. Technical and economical success of each process will depend on the appropriate process design and metal mold design for each procedure. This study aims to analyze the moldings of first and second steps among the multi-step molding processes of SCM435 bolt by use of the finite element method in order to achieve the reasonable process. Since the processes of first and second steps analyzed by use of the finite element method consist of axial symmetry, the transformed configuration of material satisfy the dimensions expected in process. In addition, the uniflow line formed in material becomes smooth and consistent over the entire process. Therefore neither molding of material nor inherent defect is expected.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.9
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• pp.32-40
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• 2004

This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. The system is composed of four main modules. The process planning and the die design modules consider several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.11
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• pp.3387-3397
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• 1996

The Hub is an auto mobile component used as aircon clutch. The important aspects in cold forging of the Hub with complex geometry are the design of an initial shape of the workpiece, the possibility of the forming by one-stage operation and the determination of number of performs, etc. Based on the systematic procedure of process sequence design, in this paper, the forming operation of cold forged part of the Hub is designed by the rigid-plastic finite element method. The two design criterion of geometrical filling without defect and an even distribution of effective strain in final product are investigated in controlling the initial shape of the workpiece and preform configuration. It is noted that one preforming operation is required in order to obtain final product of the Hub.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.47-49
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• 2008

The brake pipe is important part in automobile. The brake pipe have to prevent crack, fracture and defects for braking in safety. Especially, shape of ends of pipe has influence on ability of brake. Based on the procedure of process design, in this paper, the forming operation is designed by finite element method. Design variable and response value was selected shape of die and damage factor. To improve die that performed FEM and compared results of two types of die.