• 제목/요약/키워드: Forging load

검색결과 207건 처리시간 0.026초

내부 치형 부품의 냉간단조 공정설계에 관한 연구 (A Study on Process Design of cold Forging for Inner Tooth Part)

  • 박준모;이현철;신동초;김병민
    • 한국정밀공학회:학술대회논문집
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    • 한국정밀공학회 2002년도 추계학술대회 논문집
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    • pp.320-323
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    • 2002
  • This paper discusses process design of cold forging for inner tooth part, drum clutch. In respect to high productivity, low material consumption and low piece production costs, Metal forming has more merits than machining process. Net shape forming is huh technology which satisfies merits of metal forming and achieves high accuracy. Recently, net shape forming method widely applied because of high productivity, low material consumption and low piece production costs using press. In this study, the method which accuracy of drum clutch, automatic transmission pin, can be improved is discussed. First, process variables for process design of drum clutch are selected, and then process design is accomplished using forming analysis method. from forming analysis, forming load, stress, unfiling part is obtained. and comparing these results, optimal process design can be determined.

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재료이용률 향상을 위한 인젝터 하우징의 정밀냉간단조공정 유한요소해석 (Finite Element Analysis of Precision Cold Forging Process to Improve Material Utilization for Injector Housing)

  • 김현민;박용복;박성영
    • 소성∙가공
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    • 제20권4호
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    • pp.291-295
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    • 2011
  • The injector housing has two functions, namely, positioning the injector and protecting it from coolant. The conventional manufacturing process of the injector housing by machining has some drawbacks such as considerable loss of material and environmental pollution caused by excessive use of cutting oil. In this paper, precision cold forging is proposed as a new manufacturing process in order to improve these issues. A numerical study was conducted to compute the metal flow, strain, load and other process variables using DEFORM-2D, a finite element analysis(FEA) code for metal forming. Two process methods were investigated and optimal conditions were computed with the FEA code. A prototype was manufactured from the optimal process method and the metal flow and hardness were obtained from the prototype.

단조용 금형세트 설계용 구조해석 시스템 AFDEX/DIE (A Structural Analysis System for Forging Die Sets Design, AFDEX/DIE)

  • 전만수;이민철;류찬호;조홍석
    • 소성∙가공
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    • 제9권2호
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    • pp.165-170
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    • 2000
  • In this paper, a general approach to structural analysis of forging die sets is presented and the related design system, AFDEX/DIE, is introduced. Structural analysis of die sets is conducted by the finite element method considering both contact problem and shrink fit. In the approach, amount of shrink fit is controlled by thermal load, i.e., temperature difference between die insert and shrink rings. The loading conditions are extracted automatically from the simulation results obtained by a rigie-thermoviscoplatic finite element method. Typical application examples are given, which show the applicability of the approach and the related program.

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자유형 단조 공정에 의한 Ti-6Al-4V 빌렛 제조기술 (Manufacturing Process of the Ti-6Al-4V Billet by the Open-die Forging)

  • 김국주;최승식;황창률;김종식;염종택;이종수
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 2006년도 춘계학술대회 논문집
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    • pp.377-380
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    • 2006
  • Manufacturing process of Ti-6Al-4V alloy billet was investigated with FEM simulation and experimental analysis. Before the breakdown process of Ti-6Al-4V alloy ingot, FEM simulation for the breakdown processes of Ti-6Al-4V alloy ingot was used to calculate the forging load and state variables such as strain, strain rate and temperature. In order to breakdown the ingot structure and make an equiaxed structure billet, two different processes were employed for a VAR/VAR processed Ti-6Al-4V alloy ingot. Firstly, the ingot was cogged in single-phase $\beta$ field at the temperature of $1,100^{\circ}C$. In the process, the coarse and inhomogeneous structure developed by the double melting process was broken down. The second breakdown was performed by upsetting and cogging processes in $\alpha+\beta$ phase field to obtain the microstructure of fine equixed $\alpha$ structure in the matrix of transformed $\beta$. Finally, the mechanical properties of Ti-6Al-4V alloy billet made in this work were compared with those of other billet and ring product.

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AI7050-T7452 단조재의 피로균열성장에 대한 균열닫힘의 영향 (Effect of Crack Closure on the Fatigue Crack Growth Behavior of Forged AI7050-T7452)

  • Lee, W.S.;Park, J.Y.;Lee, H.W.
    • 한국정밀공학회지
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    • 제14권7호
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    • pp.82-90
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    • 1997
  • When a structure is made by the process of forging, it has the different mechanical properties from those it has before the process. This study is based on the crack closure phenomenon of the crack growth behavior of forged AI7050-T7452. The specimens were prepared in three kinds of forging ratio in order to find out the effects of crack closure on the forged material and compare the crack growth behavior with not-forged aluminum. COD method and strain gage method were used in measuring the crack closure stress and the results from those methods were compared each other. FEM analysis was applied to verify the effective stress intensity factor range by the superposition of the crack closure load to the crack tip. In the result of this study, the crack closure stress decreased with increasing the forging ratio due to the finer grain size and the brittle manner.

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스프링부착 금형을 가진 다단 축대칭 단조공정의 유한요소해석-단조시뮬레이터 공정적용 사례(3) (Finite Element Analysis of a Multi-Stage Axisymmetric Forging Process Having A Spring-Attached Die)

  • 전만수;이석원;정재헌
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 1996년도 춘계학술대회논문집
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    • pp.93-100
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    • 1996
  • In this paper, a computer simulationtechnique for the forging process having a spring-attached die was presented . The penalty rigid-thermoviscoplastic finite element method was empolyed together with an interatively force-balancing method, in which the convergence was achieved when the forming load and the spring reaction force are in equilibrium within the user-specified allowable accuracy. The force balance was controled by adjusting the velocity of the spring-attched die. th minimize the number of internations, a velocity estimating schemewas proposed. Two application examples found in the related company were given. In the first application example, the predicted metal folw lines were compared with the acturally forged ones. in the second example, a hot forging process with a spring-attached die was simulated and the analyzed results were discussed in order to investigated the effects of spring-attached dies on the metal flow lines and the forming loads.

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마이크로 단조 시스템을 이용한 Al 5083 초소성 합금의 마이크로 성형성에 관한 연구 (A Study on the Micro-Formability of Al 5083 Superplastic Alloy Using Micro-Forging System)

  • 손선천;강성규;박규열;나영상;이종훈
    • 소성∙가공
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    • 제14권5호
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    • pp.432-438
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    • 2005
  • Among the most of manufacturing process, plastic deformation method offers a significant advantage in productivity and enable mass production with controlled quality and low cost. From the point of view, micro forming is a well suited technology in manufacturing very small metallic parts, in particular for mass production, as they are required in many industrial products. Meanwhile, Al 5083 superplastic alloy with very small grains has a great advantage in achieving micro deformation under low stress due to its relatively low strength at a specific high temperature range. This paper describes the micro formability of Al 5083 superplastic alloy and its application to die forging of micro patterns. Micro formability tests of Al 5083 superplastic alloy were carried out with the specially designed micro forging system by using V-grooved micro dies and pyramidal dies made of (100) silicon. With these dies, micro forging was conducted by varying the applied load, material temperature and forging time The micro formability of Al 5083 superplastic alloy was evaluated by comparing $R_f$ value, where $R_f\;=\;A_f/A_v$ ($A_v$ : cross-sectional area of the flowed metal, $A_v$ : cross sectional area of V-groove). The micro formability of 3 dimensional Patterns was also evaluated using Pyramidal type micro dies.

플랜지 볼트의 플라워 형상 결함 개선을 위한 단조 금형설계 (A forging die design to improve the flower shape of flange bolt)

  • 김관우;이근태;조해용
    • Journal of Advanced Marine Engineering and Technology
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    • 제40권4호
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    • pp.314-319
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    • 2016
  • 플랜지 볼트는 체결하중을 분산시키기 위한 와셔와 같은 역할을 하는 플랜지를 가지고 있으며, 주로 냉간단조로 성형된다. 플랜지의 단조 시 꽃무늬 모양의 결함이 발생할 수 있다. 이 결함은 치수 정밀도 및 품질 저하 등의 문제점을 야기할 수 있어 이에 대한 개선이 요구된다. 본 논문에서는 플랜지 볼트의 플라워 형상 결함을 개선하기 위한 금형 설계방법을 제안하고자 하였다. 이를 위해 기존의 단조 공정에서 앞판의 내경을 변수로 금형을 수정하였다. 수정된 금형을 적용한 단조 공정은 상용 유한요소해석 코드인 DEFORM-3D를 이용하여 시뮬레이션 하였고, 해석결과를 기준으로 단조 실험을 하여 결과의 신뢰성을 검증하였다.

2단계공정을 이용한 헬리컬기어 압출에 관한 연구 (A Study on Extrusion of Helical Gears by a Two-step Process)

  • 정성윤;박준홍;김철;김창호;최재찬;최상호
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 2002년도 제7회 단조 심포지엄
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    • pp.85-91
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    • 2002
  • Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

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