• Title/Summary/Keyword: Plate Forging

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A Study on the Optimum Design for Energy Saving of an Auto Transmission Part (자동변속기용 부품의 에너지 절감을 위한 최적 설계 연구)

  • Lee, H.S.;Kim, T.H.;Kim, S.H.;Hong, E.C.;Lee, J.H.
    • Transactions of Materials Processing
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    • v.24 no.3
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    • pp.181-186
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    • 2015
  • Many in the industrial world that consume high amounts of energy are trying to reduce energy when manufacturing their products. Energy saving during manufacturing is a cost reduction. Reduced cost is necessary for profit improvement. The Piston Under Drive Brake used in the current study is an automotive transmission part. The original machining after hot forging was changed to machining after cold forging of a plate in order to save energy and cost. Two extrusion shapes along the outer diameter caused decreased tool life because of the interrupted cut during turning. Therefore, a thickness reduction of two extrusion areas in the outer diameter was needed. The current study suggests an effective way to reduce the thickness of interrupted cut by using progressive blanking.

Finite Element Analysis for Optimizing the Initial Thickness of an Under-drive Brake Piston used in a Automatic Transmission (자동변속기용 언더 드라이브 브레이크 피스톤의 두께 최적화를 위한 유한요소해석)

  • Lee, J.S.;Yoon, J.H.;Lee, J.H.;Kim, S.H.;Hong, E.C.
    • Transactions of Materials Processing
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    • v.23 no.2
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    • pp.95-102
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    • 2014
  • The under-drive brake piston is an important component in automotive transmissions. It changes the velocity by controlling the gear ratio. It has been traditionally manufactured by hot forging. Recently, there has been an effort to replace this traditional manufacturing method with cold forging in order to improve the dimensional accuracy and decrease the surface roughness. Cold forging uses a smaller amount of initial material and also has a shorter cycle time since the forged surface can be the final surface without the need of post-processing such as machining or grinding. In the current study, finite element analysis was conducted to evaluate a process design using an initial plate with reduced thickness. This smaller thickness decreases the amount of material needed for the part as well as the machining to produce the final product.

Net Shape Forming Process for Ball Stud Using High Strength Micro-Alloyed Cold Forging Steel (냉간 비조질강을 이용한 볼 스터드의 정형가공 공정연구)

  • Yoon, D.J.;Choi, H.J.;Lee, H.W.;Lee, G.A.;Jang, B.L.;Seo, S.L.;Choi, S.
    • Transactions of Materials Processing
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    • v.15 no.8 s.89
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    • pp.562-567
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    • 2006
  • Micro-alloyed steel or heat-treatment-free used in clean technology have been replacing for conventional quenched-and-tempered structural steels since the micro-alloyed forging steel was developed in early 1970s in Germany for saving money of heat treatment, simplified process, short delivery and good productivity. In this paper, ball stud assembled in steering system for automobile was selected to compare conventional process making heat treatment with new process using high strength micro-alloyed steel without heat treatment. The conventional process for ball stud was composed of a total of 6 steps including upsetting, forward extrusion, machining, burnishing and tread rolling with heat treatment and shot blasting. As opposed to conventional process, newly proposed process for ball stud using the clean technology without heat treatment is simplified such as forward extrusion, heading, upsetting, forming having a flange shape and tread rolling. Also net shape forming process to achieve specified process not to include machined step fur manufacturing the ball stud was applied to newly simplified process since micro-alloyed steel is difficult to be formed.

Quality Evaluation of Resistance Spot Welding using Acoustic Emission (음향방출을 이용한 저항 점용접의 용접 품질평가)

  • Jo Dae-Hee;Rhee Zhang-Kyu;Park Sung-Oan;Cho Jin-Ho;Kim Bong-Gag;Woo Chang-Ki
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.15 no.4
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    • pp.98-104
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    • 2006
  • In this paper, for the purpose of investigation the acoustic emission(AE) behaviors during resistance spot welding process and tension test of spec steels. As the results present the resistance spot welding method that can get suitable welding qualities or structural integrity estimating method. The resistance spot welding process consists of several stages: set-down of the electrodes; squeeze; current flow; forging; hold time; and lift-off. Various types of AE signals are produced during each of these stages. For tensile-shear test and cross tensile test in resistance spot welded specimens, fracture pa 야 ems are produced: tear fracture; shear fracture; and plug fracture. Tensile-shear specimens strength appeared higher than cross tensile specimens one. In case of tensile-shear specimen happened tear fracture that crack happens in most lower plate. Also, in case of cross tensile specimens, upper plate and lower plate are detached perfect fracture was exposed increases a little as acting force is lower than ordinary welding condition. Therefore, the structure which is combined by resistance spot welding confirmed that welding design must attain so that shear stress may can interact mainly.

Study of Forming Properties for an Edge Thickening Model Using the Finite Element Method (유한요소해석을 이용한 증육 모델의 성형특성 연구)

  • Cho, C.D.;Kim, Y.J.
    • Transactions of Materials Processing
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    • v.21 no.4
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    • pp.234-239
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    • 2012
  • This study examines the forming properties and forming loads needed to increase the edge thickness on the external face of a plate using finite element analysis(FEA). Recently, forming optimization techniques within FEA are being extensively used in designing the optimal forming conditions for processes like forging, extrusion, rolling, and spinning. Most of these existing forming operations involve reducing the volume per unit length, but research for increasing volume per unit length is not very extensive. For this study we chose an automotive engine flywheel which is a welded assembly of a plate and a gear with each component having a different thickness. We considered a forming technique to increase the thickness in order to allow the machining of the gear directly on the external face of plate alleviating the need for a weld. To study various forming techniques, we used the finite element method with the flow stress of material and incremental forming steps. We conclude from this study that the analysis of forming properties and forming loads by using the finite element analysis and testing is useful as a method to increase the thickness per unit length.

Fabrication of a sterling silver ring with folding process (폴딩 기법을 이용한 스털링실버 링 제조 공정)

  • Kim, Ik gyu;Kim, Kwangbae;Kim, Eun-Seok;Song, Ohsung
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.20 no.9
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    • pp.382-389
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    • 2019
  • A novel folding process is proposed using a repeated cold-die forging and annealing to form a sterling silver ring. Sterling silver plate was cut into a doughnut shape, and lattices with 0.43-mm line-width were imprinted on it. The sample was folded by forging using dies with slopes of $45^{\circ}$, $60^{\circ}$, and $75^{\circ}$ and annealing. For comparison, samples were also fabricated without annealing. Strain was identified by measuring the length of lattices. Vernier calipers, a Vickers hardness tester, an optical microscope, and a UV-VIS colorimeter were used to determine the size, hardness, microstructure, and body color. Without annealing, cracks occurred. However, successful deformation was possible when annealing was used. The results of macro strain measurements show that the outer diameter and width decreased, while the inner diameter and thickness increased after the final process. The maximum strain was increased 0.128 toward the parallel direction. The Vickers hardness decreased after annealing and increased after the folding process. The microstructure results showed that the grain size increased after annealing but decreased after folding. The color difference based on the Lab index was under 10 for all processes. Eventually, a doughnut-shaped silver plate was successfully deformed into a ring shape by the folding process.

Atmospheric Corrosion of 7B04 Aluminum Alloy in Marine Environments

  • Zhang, Xiaoyun;Liu, Ming;Lu, Feng;Liu, Minghui;Sun, Zhihua;Tang, Zhihui
    • Corrosion Science and Technology
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    • v.17 no.1
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    • pp.6-11
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    • 2018
  • Outdoor exposure tests using of 7B04 aluminium alloy samples including plate, tensile and various SCC samples were carried out in Tuandao station, Shandong province (East of China) and Wanning station, Hainan province (South of China). Corrosion characteristics including weight loss, microstructure, tensile strength and SCC susceptibility were investigated. The corrosion rates in Tuandao and Wanning showed high to low and the corrosion rates changed to the following equation of $w=at^b$ (b<1). The corrosion of 7B04 aluminium alloy in Wanning was more serious than that in Tuandao. Pitting appeared at early stage of expose test, and it can be changed to general corrosion with test time extension. The 7B04 aluminium alloy of which specimen shapes are forging and thick plate also showed SCC (Stress corrosion cracking) in the marine atmosphere. The higher SCC sensitivity was observed in Wanning station than in Tuandao station. The 7B04 aluminium alloy with a high stress level was more sensitive to SCC. Intergranular and transgranular or a mixed mode of cracking can be observed in different marine exposure.

The effects of die design parameters on shearing of the thin plate (정밀금형의 설계인자의 박판 전단가공특성에 미치는 영향)

  • 신용승;김병희;김헌영
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1997.10a
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    • pp.523-526
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    • 1997
  • Sheanng is one of the most important operating processes in the field of sheet metal manufacturing. Compared with casting, forging and machining, shearing is very economical to obtain the desired shape. In recent years there has been increasing the use of shearing process in the manufacturing of small and light electronic components. In this paper, it has been researched the experimental investigation to examine the mfl uence of shearing process parameters such as clearance and lower holder configuration. Through the experiment results, the more narrow clearance gives the smaller burr height and the removal of lower holder makes the worse sheared surface. And FE simulation of shearing process using DEFORM-2D were camed out and the results compared w~th experimental studies

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Jangdo(Small Ornamental Knives) manufacturing process and restoration research using Odong Inlay application (오동상감(烏銅象嵌)기법을 활용한 장도(粧刀)의 제작기술 및 복원연구)

  • Yun, Yong Hyun;Cho, Nam Chul;Jeong, Yeong Sang;Jang, Chu Nam
    • Korean Journal of Heritage: History & Science
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    • v.49 no.2
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    • pp.172-189
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    • 2016
  • In this research, literature research on the Odong material, mixture ratio, casting method and casting facility was conducted on contemporary documents, such as Cheongong Geamul. Also, a long sword was produced using the Odong inlay technique. The sword reproduction steps were as follows; Odong alloying, silver soldering alloying, Odong plate and Silver plate production, hilt and sheath production, metal frame and decorative elements, such as a Dugup (metal frame), production, Odong inlay assembly and final assembly. For the Odong alloy production, the mixture ratio of the true Odong, which has copper and gold ratio of 20:1, was used. This is traditional ratio for high quality product according to $17^{th}$ century metallurgy instruction manual. The silver soldering alloy was produced with silver and brass(Cu 7 : Zn 3) ratio of 5:1 for inlay purpose and 5:2 ratio for simple welding purpose. The true Odong alloy laminated with silver plate was used to produce hilt and sheath. The alloy went through annealing and forging steps to make it into 0.6 mm thick plate and its backing layer, which is a silver plate, had the matching thickness. After the two plates were adhered, the laminated plate went through annealing, forging, engraving, silver inlaying, shaping, silver welding, finishing and polishing steps. During the Odong colouring process, its red surface turns black by induced corrosion and different hues can be achieved depending on its quality. To accomplish the silver inlay Odong techniques, a Hanji saturated with thirty day old urine is wrapped around a hilt and sheath material, then it is left at warm room temperature for two to three hours. The Odong's surface will turn black when silver inlay remains unchanged. Various scientific analysis were conducted to study composition of recreated Odong panel, silver soldering, silver plate and the colouring agent on Odong's surface. The recreated Odong had average out at Cu 95.57 wt% Au 4.16wt% and Cu 98.04 wt% Au 1.95wt%, when documented ratio in the old record is Cu 95wt% and Au 5wt%. The recreated Odong was prone to surface breakage during manufacturing process unlike material made with composition ratio written in the old record. On the silver plate of the silver and Odong laminate, 100wt% Ag was detected and between the two layers Cu, Ag and Au were detected. This proves that the adhesion between the two layers was successfully achieved. The silver soldering had varied composition of Ag depending on the location. This shows uneven composition of the silver welding. A large quantities of S, that was not initially present, was detected on the surface of the black Odong. This indicates that presence of S has influence on Odong colour. Additional study on the chromaticity, additional chemical compounds and its restoration are needed for the further understanding of the origin of Odong colour. The result of Odong alloy testing and recreation, Odong silver inlay long sword production, scientific analysis of the Odong black colouring agent will form an important foundation of knowledge for conservation of Odong artifact.

A Study on Edge Bridge Minimization of Fine Blanking Process (Fine Blanking의 가장자리 Bridge 최소화 방법에 관한 연구)

  • Kim, Gi-Tea
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.12 no.4
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    • pp.108-113
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    • 2013
  • Industrialization and modernization of the beginning of the IT industry is growing very fast. Since telecommunications industry was developed rapidly, technologies about miniaturization and high-precision of parts have been actively developed to lead information revolution. generally, the entire shear surface of the product applying fine blanking technology must be very precise. Fine blanking is used to save cost by avoiding post-processing of the product. When using press blanking, it spends a lot of money on the production by using many post-processing. Fine blanking typically used in 0.5~18 mm thick steel plate. Because a lot of post-processing cost can be used to process, except for fine blanking. In order to develop components "CHANCE CONTENTS" in the fine blanking process, the purpose of this study is to minimize the edge of the bridge, secured 95% of the material thickness of the shear surface using the 1.6 mm thickness of the material SPCC. Blanking process by introducing after changing thickness through forging process, due to change in vee-rring force and counter force, the experimental amount of depressions and flatness and the shear surface were analyzed.