• Journal of the Korean Society for Precision Engineering
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• v.15 no.10
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• pp.51-57
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• 1998

In this paper, a computer aided process design technique, utilizing a forging simulator and a commercial CAD software, is presented together with its related design system for cold-former forging of ball joints. The forging sequence design is carried out through user-computer interaction by using design templates, design database, experience or knowledge-based rules and some basic laws found in the literature. The forging simulation technique is used to verify the process design. The detail designs including die set drawings and die manufacturing information are automatically generated. It has been shown that the engineer ing and design productivity is much improved by the presented approach in the practical standpoint of process design engineers.

• Journal of the Korean Society for Precision Engineering
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• v.7 no.2
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• pp.95-104
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• 1990

This paper descirbes some research of Computer-aided Design of multi-stage cold forging die of rotationally symmetric parts produced by the press or former. An approach to the system is based on knowledge based system. Knowledges for tool design are extracted from the plasticity theory, handbooks, relevent references and empirical know-how of experts in cold forging companies. The deveoped system is composed of three main modules such as die design module, punch design module, tool elements design module which are sued independently or in all. Using this system, design parameters (types of dies, geometric shapes and dimensions of dies, types of punches, geometric shapes and dimensions of punches, geometric shapes and dimensions of tool elements) in each operation are determined and the output is generated in graphic form. The develpoed system, aids designer, provides powerful capability for designing dies, punches and tool elements.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.3
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• pp.165-171
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• 2003

In a structure, many components are fastened together using bolts, nuts and rivets through drilled holes. Not only do these fastened joints enable easy assembly and dismantling, they are also able to transfer as well as to distribute loads applied onto the structures. The major drawback of such connections, however, is that the fatigue life of the components is reduced by the presence of the hole since the stress concentration around the hole is increased. In addition, the hole drilling process itself may introduce defects or roughness at the surfaces of the hole that may cause further decrease in fatigue performance of the components. For applications where fatigue loadings are important, one way to compensate the decrease in fatigue life of the components is by introduction of beneficial compressive residual stress around the hole using cold working. The material used for this research were A12024-T351 and A17050-T7451 using the primary member of aircraft. We present, In this paper, the characteristics of coldworking by evaluation of the hole expansion ratio, residual stress distribution, and fatigue properties.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.3
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• pp.94-101
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• 1996

This paper presents an investigation of the ability of the scheme to simultaneously accomplish both prediction of fracture initiation and analysis of deformation in cold forged products. The Cockcroft-Latham criterion which is successfully applied to a variety of loading situations is used in the present investigation to estimate if and where surface and internal fracture occur during the deformation process. The numerical predictions and experimental results of two types of fundamental cold metal forming process taken into account are compared. Finite element simulation combined with fracture criterion has successfully predicted the site of surface or internal fracture initiation and corresponding to level of deformation observed experimentally.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.11
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• pp.977-982
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• 2015

This study uses finite element analysis to evaluate the forming load of tool entrance angle of the cold forward extrusion molding process of helical gear; this can replace the spur gear applied to the Electronic Parking Brake (EPB) system. A cold forging process is often used in the automobile industry as well as in various industrial machines due to its high efficiency. Finite element analysis is frequently used when interpreting results of the forging process. Formality was evaluated by calculating tooth profile filling rate of helical gear. Change in required forming load was investigated when the entrance angle of forward extrusion tool die was changed from $30^{\circ}$ to $60^{\circ}$, also by finite element analysis. We suggest suitable tool entrance angles.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.6
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• pp.86-95
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• 2002

This paper suggests the new technology to control metal flow in order to reduce the number of preforming and the machining for the cold forged product with complex geometry. This technology is the combined forming that consists of bulk and sheet forming with double action dies. To analyze the process, finite element simulation has been performed. The proposed technology is applied to hub model that is part of air conditioner clutch. The purpose of this study is to investigate the material now of hub through the relative-velocity control of punch and mandrel using the flow control forming technique.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.1
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• pp.107-118
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• 2002

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 of quasi-axisymmetric cold forging product by cold former working. 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. 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 three main modules and five sub-modules. The process planning and die design module considers several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available cold farmer, and the availability of standard parts. As the system using 2D geometry recognition is integrated with the technology of process planning, die design, and CAE analysis, the standardization of die parts for wheel bolt requiring cold forging process is possible. The developed system makes it possible to design and manufacture quasi-axisymmetric cold forging product more efficiently.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.784-789
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• 2001

In order to investigate the fracture behaviors(penetration modes) and the resistance to penetration during ballistic impact of cold-rolled Al 5052 H34 alloy laminates, anodized Al 5052 H34 alloy laminates, and Al 5052 H34 alloy after cold-rolling, ballistic testing was conducted. In general, superior armor material is brittle materials which have a high hardness. Ballistic resistance of these materials was measured by protection ballistic limit(V50), a statical velocity with 50% probability for incomplete penetration. Fracture behaviors and ballistic tolerance, described by penetration modes, are observed respectfully, resulting from V50 test and Projectile Through Plate(PTP) test at velocities greater than V50. PTP tests were conducted with 0$^{\circ}$obliquity at room temperature using 5.56mm ball projectile. V50 tests with 0$^{\circ}$obliquity at room temperature were also conducted with projectiles that were able to achieve near or complete penetration during PTP tests. Surface Hardness, resistance to penetration, and penetration modes of Al 5052 H34 alloy laminates compared to those of cold-rolled Al 5052 H34 alloy laminates and anodized Al 5052 H34 alloy laminates anodized Al 5052 H34 alloy after cold-rolling.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.3
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• pp.383-388
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• 2011

The cold hollow cathode gas ion source is under development for multi aperture focused ion beam (FIB) system. In this paper, we describe the cold hollow cathode ion source design and the general ion source performance using Ar gas. The glow discharge characteristics and the ion beam current density at various operation conditions are investigated. This ion source can generate maximum ion beam current density of approximately 120 mA/$cm^2$ at ion beam potential of 10 kV. In order to effectively transport the energetic ions generated from the ion source to the multi-aperture focused ion beam(FIB) system, the einzel lens system for ion beam focusing is designed and evaluated. The ions ejected from the ion source can be forced to move near parallel to the beam axis by adjusting the potentials of the einzel lenses.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.5
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• pp.63-68
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• 2010

The use of aluminum alloy parts in the automotive industry has been increasing recently due to its low weight compared with steel to improve fuel efficiency. Companies in the auto parts' manufacturing sector are expected to meet the government's strict environmental regulations. In this study, manufacturing process of aluminum alloy bolt has been designed from forming to heat treatment. Bolt forming process is composed of cold forging for body and rolling for thread. In this study only cold forging process is considered by employing the finite element method. In the cold forging process, preform shape was designed and damage value was considered for die design. Two steps of forging process has been developed by the simulation and a prototype was manugactured accordingly. As a final process, solution heat treatment and aging process was employed. A final prototype was found to meet the required specifications of tensile strength and dimension.