• Journal of the Korean Society for Precision Engineering
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• v.23 no.11 s.188
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• pp.78-84
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• 2006

The objective of this study is to design the optimal die profile that can prevent material fracture in the tube drawing process for automobile steering input shaft. First, the CDV(Critical Damage Value) of material is obtained by the compression test and FE-analysis. The occurrence of fracture is estimated by the FE-analysis considering the CDV. In order to achieve the objective of this study, optimization technique and FE-analysis are applied. FPS(Flexible Polyhedron Search) method, which is one of the non-gradient optimization techniques often used in engineering, is used to search optimal die profile. The drawing die profile is represented by Bezier-curve to generate all the possible die profile. Using FPS method and FE-analysis the optimal drawing die profile is determined. To verify tile effectiveness of the redesigned optimal die, the tube drawing experiment is performed. In the experimental result, it is possible to produce sound product without material fracture using the redesigned optimal die.

• Transactions of Materials Processing
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• v.8 no.5
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• pp.471-481
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• 1999

The properties of deformed products are generally dependent upon the distribution of microstureture. It is, therefore, necessary to make the distribution of microstureture uniform in order to achieve the best balance of properties in the final product. This is often a demanding task, even for conventional materials. It is become essential to achieving mechanical integrity and a desired combination of microstructure and properties. The objective mechanical integrity and a desired combination of microsttucture and properties. The objective of this study is to design the optimal die profile which can yield more uniform microstructure in hot extruded product. The microstructure evolution, such as dynamic and static recrystallization as well as grain growth, is investigated using the program com-bined with yada and Senuma's empirical equations and rigid-thermoviscoplastic finite element method. The die profile of hot extrusion is represented by Bezier-curve to define all available profile. In order to obtain the optimal die profile which yields uniform microstructure in the product the FPS(Flexible Polyhedron Search) method is applied to the present study. To validate the result of present study the experimental hot extrusion is performed and the result is compared with that of simulation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.1
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• pp.69-74
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• 2003

The purpose of the present paper is to investigate about the machining of profile (core/cavity) of mold die using the commercial CAM system. Recently the requirement of the light weight and high performance of automobiles has Increased. The weight of the automobile is very important in the viewpoint of the fuel and traveling performance. The optimal design technique, material technique, the process design for parts and specially, die machining technique need to be developed for increasing productivity and reducing production time of the automobile parts. In this study, the effect of machining condition on precision of die profile is investigated by experimental observation and analysis. The results will be reflected for development of the precision die of the automobile.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.3
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• pp.453-458
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• 1992

본 연구에서는 유한요소법에 바탕을 둔 최적공정설계법을 이용하여 압출 금형 형상의 최적설계를 실시하였다.설계의 결과를 참고문헌에서 발췌한 이론해와 비교 하였으며, 축대칭 압출공정에서 압하율, 마찰, 재료특성 등이 금형의 최적형상에 미치 는 영향에 대하여 조사하였다.

• Transactions of Materials Processing
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• v.5 no.4
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• pp.269-280
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• 1996

A new approach to die shape optimal design in extrusion is presented. The approach consists of a FEM analysis model to predict the value of the objective function a design model to relate the die profile with the design variables and a genetic algorithm based optimaization procedure. The approach was described in detail with emphasis on our modified micro genetic algorithm. Comparison with theoretical solutions was made to examine the validity of the predicted optimal die shapes. The approach was then applied to revealing the optimal die shapes with regard to various objective functions including those for which the design sensitivities can not be deter-mined analytically.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.209-212
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• 2007

Rubber compounds have high viscoelastic property. One of the viscoelastic behaviors during profile extrusion is the swelling of extrudate. In this study, die swell of rubber compounds at the capillary die have been investigated through an experiment and computer simulation. They have been performed using fluidity tester in experiment and commercial CFD code, Polyflow in computer simulation. Die swell of rubber compounds for relaxation time at several modes under same conditions with the experiment were predicted using non-linear differential viscoelastic model, Phan-Thien-Tanner (PTT) model. The simulation was analyzed compared with the experiment. Viscoelastic behaviors for pressure, velocity and shear rate distribution were analyzed at the capillary die. It is concluded that the PTT model successfully represented the amount of the optimal die swell of rubber compounds for relaxation time at different modes.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.519-523
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• 1996

The polishing tool unit is developed which can be attached on the machining center and automatic polishing system for die and mold is also established. So, experiments are carried out under the several polishing conditions. The polishing properties of automatic polishing operation such as surface roughness, stock removal and maximum profile valley depth are obtained and analyzed quantitatively for each polishing tool. The purpose of this study is to construct an expert system for optimal condition of die and mold automatic polishing using the knowledge base that is obtained in the polishing experiments and, to verify the feasibility of the expert system through the experiments. Using this expert system, unskilled operators will be able to obtain the knowledge and experience of an expert.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.1
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• pp.120-126
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• 2002

The near net shape forging of gears offers significant technical and economic advantages ever other forms of manufacture. These potential benefits can however only be realized by careful die design. This paper describes a computer-based methodology fur achieving this. A Visual-BASIC program has been developed on a rule based system that enables optimal design of the dies taking into account the elastic deflections generated in shrink-fitting the die inserts and that caused by the stresses generated in the forging process. The method also enables the profile of the spark erosion electrode to be determined. An example of the application to forging spur gears is given.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.2
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• pp.137-143
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• 1999

The study of the high speed machining of inclined plane using ball end mill is performed. The use of ball end mill is rapidly growing in die and mold manufacturing. The cutting characteristics, such as cuttin g force, surface roughness and surface profile, are varied according to the variation of cutting directions. Free surface is cut using ball end mill, the surface profile is greatly varied depending upon the cutting direction. So this study will deal with the characteristics of cutting such as cutting efficiency according to the inclined plane of the workpiece, the cutting force according to tool path, surface profile and the roughness of surface. The optimal cutting direction to be applied the cutting for 3-D sculptured surfaces can be show through the results of this study.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.723-730
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• 2004

This paper describes the analysis of extrusion process and integrity for a condenser tube which is a component of the heat exchanger in automobile and all conditioning apparatus. Recently, according to the development of analysis method using the computer, the numerical simulation have been applied to the 3-dimensional hot extrusion process with complex section area of the non-steady statement and then results of the analysis have been applied to optimal die design and process design. In this paper, firstly, the die design was performed for a condenser tube with a multi-hole section and the rigid-plasticity FE analysis performed of extrusion process. Secondly, we estimated metal flow of billet, extrusion load, welding pressure in chamber etc. and evaluated the pressure and elastic strain of the die land and mandrel tooth profile through a stress analysis of the die. Finally, the extrusion test was performed to estimate the validity of FE analysis. This paper confirmed that the designed extrusion die of the research is satisfactorily designed fur integrity of condenser tube.