• Title/Summary/Keyword: Forging load

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A Study on the Improvement of Forming Process of Power Assisted Steering Part (PAS부품의 공정개선에 관한 연구)

  • 윤대영;황병복;유태곤
    • Transactions of Materials Processing
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    • v.9 no.3
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    • pp.265-273
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    • 2000
  • The conventional and new forging processes of the power steering worm blank are analyzed by the rigid-plastic finite element method. The conventional process contains three stages such as indentation, extrusion and upsetting, which was designed by a forming equipment expert. Process conditions such as reduction in area, semi-die angle and upsetting ratio are considered to prevent internal or geometrical defects. The results of simulation of the conventional forging process are summarized in terms of deformation patterns, load-stroke relationships and die pressures for each forming operation. Based on the simulation results of the current three-stage, the power steering worm blank forging process for improving the conventional process sequence is designed. Die pressures and forming loads of proposed process are within limit value which is proposed by experts and the proposed process is found to be proper for manufacturing the power steering worm blank.

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TIME DELAYED CONTROLLER를 이용한 유압 시스템의 위치 제어

  • 진성무;현장환;이정오
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2001.10a
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    • pp.204-208
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    • 2001
  • Position control of the electro-hydraulic servo indexing system in a flexible forging machine was investigated Flexible forging machine forges an axial type workpiece in the radial direction as well as in the axial direction. The role of the indexing system is to rotate a workpiece fast and accurately to a desired position for continuous shaping. Since the inertia of a workpiece changes during each forging step, a control technique which is robust to inertia variation should be adopted to the position control of the workpiece. In this study, time delayed control technique is applied to the servo system. Time delayed control method does not depend on estimation of specific parameters. Rather, it depends on the direct estimation of a function representing the effect of uncertainties. Direct estimation is accomplished using time delay and the gathered information is used to cancel the unknown dynamics is accomplished using disturbances simultaneously. Experimental result show that the time delayed controller is robust to inertia variation of the load, and satisfactory performance on the sposition accuracy is obtained compared to the contentional feedback control.

Comparision between Forward Extrusion and Upsetting Process for Preform with Stepped Shape (단 달림 형상의 예비성형체 성형에 대한 전방압출과 업셋팅 공정의 비교)

  • Song D. H.;Park Y. B.;Kim M. E.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2000.10a
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    • pp.82-85
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    • 2000
  • In cold forging, the final product is usually given by multi-stage process and the preform with stepped shape can be manufactured through the various forging method. The forward extrusion and upsetting processes for preform with stepped shape have been analyzed by using the rigid-plastic finite element analysis code, InteFORM and compared for load and stroke according to ae reduction of weを An engineer should select the proper processes considering the capacity and the stroke of the corresponding press in the forging of the preform with stepped shape.

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Application of FEM to the Forming Process of Disk-Brake Piston (유한요소법을 이용한 disk-brake piston의 공정설계)

  • 황병복;이호용
    • Transactions of Materials Processing
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    • v.3 no.2
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    • pp.178-188
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    • 1994
  • A design methodology is applied for manufacturing a disk-brake piston component. The design criteria are the limit drawing ratio and the forging load within the available press limit. Also, the final product should not have any geometrical defect. The rigid-plastic FEM has been applied to simulate the conventional four stage manufacturing processes, which include deep drawing and forging process. Simulation of one stage process from a selected stock to the final product shape is performed for generating information on additional requirements for metal flow. Two stage forming processes with different punch corner and nose geometries are also simulated to identify the possible best solutions. Finally, the best manufacturing process is selected, which is using a hemispherical punch int he deep drawing process.

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A COLD FORGING OF HELICAL GEAR FOR STEERING PINION

  • Kim M.E.;Kim Y.G.;Choi S.;Na K.H.;Lee Y.S.;Lee J.H.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2003.10b
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    • pp.59-62
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    • 2003
  • The precision cold forging of helical gear for steering pinion has been studied. Because of the large helix angle, there are many difficult problems to control the material flow and part dimension. The die shape was proposed to improve the flow of workpiece. In order to improve the dimensional accuracy of forged part, a FE analysis was performed. The proposed die shape drives to flow amicably workpiece. The applied load was reduced up to 10 percent, compared to the conventional-shaped-die. The elastic deformation of die has been investigated quantitatively by the 3-dimensional FE analysis. The die-land has been expanded up to $10{\mu}m$ on loading stage, based on the FEM results. Therefore, the elastic deformation amounts should be taken into consideration to improve the dimensional accuracy of forged helical gear.

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A Study on the Computer Aided Process Design of Multi Stage Cold Forging of Rotationally Symmetric Parts (축 대칭 다단 냉간단조의 공정 및 금형 설계자동화에 관한 연구(I))

  • Choi, Jae-Chan;Kim, Hyung-Sub;Huh, Man-Jo
    • Journal of the Korean Society for Precision Engineering
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    • v.6 no.4
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    • pp.84-93
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    • 1989
  • This paper describes some development of Computer-Aided Process Planning System for cold-forging of rotationally symmetric parts(soild shape and solid-can combined shape) produced by the presses or formers. Using the developed system, forming sequences for producing final product are generated as graphic forms and process names, preform dimensions and process parameters(load, punch pressure, die pressure) are generated as routing sheets. Konwledges for forming sequence and process parameters are extracted from process limitations, plasticity theories, handbooks, relevent refferences and empirical know-how of experts in cold forging companies. Among extracted knowldeges, general and consistent knowledges are represented as design rules and are constructed as knowledge base. The developed system provides more powerful tool for through checking the producibilities of design, conformation of appropriate forming sequences and discoveries of new possibility. The results of the developed system are in good agreement with the practical data.

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A Study on Developementof UBST Program for Axisymmetric Metal Forming Process (축대칭 성형공정에 대한 유동함수 상계요소법의 프로그램 개발에 관한 연구)

  • 김영호;배원병;박재우;엄태준
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1995.03a
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    • pp.124-130
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    • 1995
  • An upper-bound elemental stream function technique(UBST) is proposed for solivng forging and backward extrusion problems that are geometrically complex or need a forming simulation . And in the forging problems, this study investigates that layer of elements effects dissipation of total energy and load. The element system of UBSTuses the curve fitting property of FEM and the fluid incompressiblity of the stream function . The foumulated optimal design problems with constraints ae solved by the flixible toerance method. In the closed-die forging and backward extrusion, the result of layer of element by this study produces a lower upper-bound solution than that fo UBET and conventional layer of element . And the main advantage of UBST program is that a computer code, once written , can be used for a large variety problems by simply changing the input data.

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A Study on the Hot Free Forging of Heavy Rotors Using Conventional Dies (평다이를 이용한 대형로타의 자유단조에 관한 연구)

  • 이경호;조종래;배원병
    • Transactions of Materials Processing
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    • v.6 no.3
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    • pp.203-212
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    • 1997
  • In this research, to obtain the optimal die width of CV die(conventional die), which replaces FM die in free forging of large scale rotor using the flat die, the model material experiments and theoretical analysis using three dimensional FEM are performed. The FM die, which was designed to remove Mannesmann's effect at the central part of the ingot, has very bad workabiltity in real field, therefore on the empirical base they use the CV die of wide width in actual working field. In this study, the excellency of CV die is proved quantitively, and the optimal die width of CV die is determined through the model material experiments and theoretical analysis using FEM in the point of effective strain, stresses, and load.

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A Study on the Determination of Initial Biller for Axisymmetric Cold Forging Products Using Neural Networks (신경망을 이용한 축대칭 냉간 단조품의 초기 소재 결정에 관한 연구)

  • 김영호;배원병;박종옥
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1994.10a
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    • pp.217-222
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    • 1994
  • This paper describes the determination of optimal initial billet size for axisymmetric cold forging products using neural networks. The determination of optimal initial billet size is very important in forging design and forming sequence design, because the result of such designs and forming load can be different by variable initial billet sizes. The forming difficulty has been defined as the degree of difficulty in forming by 3 process ' forward extrusion, backward extrusion and upsetting. By neural networks a forming difficulty can be determined with the ratio of shape and forming process. From the graph of maximum, minimum, and average forming difficulties by variable billet sizes, the optimal billet size can be determined. The initial billets of a solid part and a hollow part whichwas determined by this study are compared with the sequence drawing generated by the one of forming sequence design system.

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A Study on the Process Design of Non-Axisymmetric Forging Components (비축대칭 형상의 단조 공정 설계에 관한 연구)

  • Kim, Y.H.;Bae, W.B.;Park, J.H.
    • Journal of the Korean Society for Precision Engineering
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    • v.12 no.10
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    • pp.57-68
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    • 1995
  • An upper bound elemental technique (UBET) program has been developed to predict forging load, die-cavity filling, preform in non-axisymmetric forging. To analyze the process easily, it is suggested that the deformation is divided into two different parts. Those are axisymmetric part in corner, plane-strain part in lateral. The plane-strain and axisymmetric parts are combined by building block method. And the total energy is computed through combination of three deformation parts. A dumbbell-type preform has been obtained from height and volumetric compensations of the billet based on the backward simulation. Experimetns have been carried out with pure plasticine at room temperature. Theoretical predictions are in good agreement with expereimental results.

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