• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 추계학술대회 논문집
• /
• pp.645-648
• /
• 2005

The rotational barrel type equipment has been designed for the new rheology fabrication process. During the continuous rotation of barrel with a constant temperature, the shear rate is controlled with the rotation speed and rotation time of barrel. The barrel surface can be controlled the temperature by the induction heating and cooling system. Many experiments were widely examined by using this system with controlling the rotation speed and the rotation time. The possibility for the rheoforming process was investigated with microstructural characteristics.

• 한국정밀공학회지
• /
• 제14권8호
• /
• pp.92-100
• /
• 1997

An upper-bound elemental technique (UBET) analysis is carried out to improve the material flow and to reduce the load of bearing-race forming process. The UBET analysis, which adapts the advantages of stream function and finite element method, is useful for predicting the profile of complex geometric bound- ary. From the UBET analysis, the forming load, the velocity distribution and the stream line of the deformed billet are determined by minimizing the total power consumption with respect to chosen parameters. The results of present UBET analysis are better than those of previous UBET analysis. Experiments have been carried out with model material plasticine billets at room temperature. The theoretical predictions for forming load and flow pattern(stream line) are in good agreement with the experimental results.

• 한국산학기술학회논문지
• /
• 제16권6호
• /
• pp.3692-3697
• /
• 2015

나사는 나선형의 홈으로 구성된 체결용 기계요소이다. 최근의 모바일 기기의 소형화 추세로 인하여 나사의 소형화 및 경량화 요구도 크게 증가하고 있는 실정이다. 우수한 기계적 성질과 높은 정밀도의 나사를 생산하기 위해서는 금형 및 공정설계가 성공적으로 수행되어야 한다. 본 연구에서는 유한요소해석을 통하여 초소형 나사의 머리부 냉간 단조 성형에 대한 공정설계를 수행하였다. 특히, 금형의 형상과 마찰력이 성형에 미치는 영향을 분석하기 위하여 실험계획법을 적용하였고, 그 결과 마찰력이 성형 시 발생하는 접힘 결함의 지배적인 요인임을 밝혀내었다. 이러한 결과로부터 금형 형상을 개선하였고, 개선된 금형으로 단조 실험을 수행하였고, 실험 결과로부터 접힘 결함 불량이 해소된 것을 확인하였다.

• 한국정밀공학회지
• /
• 제16권9호
• /
• pp.41-47
• /
• 1999

The scale of dendritic structure of a cast preform plays a key role in determining the mechanical properties of cast/forged products. In this study, casting experiments are carried out to reduce dendrite arm spacing (DAS) to smaller than 20 ${\mu}$m by increasing cooling rate of the mold and then to spheriodize dendritic structures by addition of alloying elements such as Zr and Ti-B. From the casting experiments, appropriate casting conditions for producing the cast preform of a motorcycle connecting rod are obtained. To obtain fine microstructures of the cast preform, mold temperature must set to be low whilst cooling rate being high. When cooling rate is 10 $^{\circ}C$/s, the size of DAS is 17.4 ${\mu}$m. And the degree of spheriodization of a grain in the cast preform is described by aspect ratio, which is defined as the ratio of major and minor radii of an elliptical grain. When 0.5% Zr and 0.24 % Ti+B are added to the molten aluminum alloy, the best aspect-ratio 0.75 is obtained. After forging the cast preform of a motorcycle connecting rod, the microstructure and mechanical properties of the cast preform are compared with those of the cast/forged product. Cast/forged products are superior in microstructure and in mechanical properties such as ultimate strength, elongation, and hardness.

• 한국정밀공학회지
• /
• 제21권9호
• /
• pp.32-40
• /
• 2004

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 for axisymmetric products. 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 four main modules. The process planning and the die design modules consider several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 추계학술대회 논문집
• /
• pp.649-652
• /
• 2005

It is reported that semi-solid forming process takes many advantages over the conventional forming process, such as long die lift, good mechanical properties and energy saves. Rheology material has a thixotropic, pseudo-plastic and shear-thinning characteristic. Therefore, general plastic or fluid dynamic analysis is not suitable for the behavior of rheology material. So it is difficult for a numerical simulation of the rheology process to be performed because complicated processes such as the filling to include the state of the free surface and solidification in the phase transformation must be considered. Moreover, it is important to predict the deformation behavior for optimization of net shape forging process with semi-solid materials and to control liquid segregation for mechanical properties of materials. In this study, so, molecular dynamics simulation was performed for the control of liquid segregation in compression experiment as a part of study on analysis of rheology forming process.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 춘계학술대회 논문집
• /
• pp.607-610
• /
• 2005

A remeshing algorithm using tetrahedral elements has been developed, which is adapted to the mesh density map constructed by a posteriori error estimation. In the finite element analyses of metal forging processes, numerical error increases as deformation proceeds due to severe distortion of elements. In order to reduce the numerical error, the desired mesh sizes in each region of the workpiece are calculated by a posteriori error estimation and the density map is constructed. Piecewise density functions are then constructed with the radial basis function in order to interpolate the discrete data of the density map. The sample mesh is constructed based on the point insertion technique which is adapted to the density function and the mesh size is controlled by moving and deleting nodes to obtain optimal distribution according to the mesh density function and the quality optimization function as well. After finishing the redistribution process of nodes, a tetrahedral mesh is constructed with the redistributed nodes, which is adapted to the density map and resulting in good mesh quality. A goodness and adaptability of the constructed mesh is verified with a testing measure. The proposed remeshing technique is applied to the finite element analyses of forging processes.

• 한국정밀공학회지
• /
• 제19권9호
• /
• pp.166-171
• /
• 2002

The objective of this paper is to investigate the effect of clearance and the configuration of die system on burr formation by FEM analysis and experimental tests. Compared with casting, forging and machining, shearing has been known, especially in heavy or mass-production industries, as a very economical and fast way to obtain the desired shape Recently, the shearing process becomes widely used in the small and light electronic component manufacturing industries. When shearing a part of sheet metal, the burr formed on the cutting edge is usually unavoidable. The burr would not only degrade the precision of products but also causes additional cost for the deburring process. In this paper, the influence of shearing parameters such as clearance and configurations of the lower pad (ejector) on burr formation is investigated by using the experimental and numerical approach. From the experimental results, it has been shown that the more narrow clearance gives the smaller burr height and the higher shearing forces. The removal of lower holder also makes the sheared surface integrity and the dimensional accuracy become worse. The FEM results (using DEFORM-2D) show good agreement with the experimental results.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2000년도 추계학술대회 논문집
• /
• pp.575-578
• /
• 2000

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation for the die wear is too hard because the prediction of the die wear is determined with many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard's wear model in order to reduce the rapid wear rate that is generated for the backward extrusion product exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat, angle, and round of the punch nose part. As the flat and angle of the punch nose are larger, the surface expansion is reduced. and, the wear rate is decreased according to the reduction of the punch round. These results obtained through this study are applied to the real manufacturing process, it is implemented the reduction of the wear rate.

• 한국정밀공학회지
• /
• 제21권10호
• /
• pp.180-187
• /
• 2004

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation fur the die wear is too hard because the die wear is caused by many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard wear model in order to reduce the rapid wear rate that is generated for the backward extruded products exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat diameter, angle, and round of the punch nose part. As the flat diameter and angle of the punch nose are larger, the surface expansion is reduced and the wear rate is decreased according to the reduction of the punch round. These results obtained through this study can be applied to the real manufacturing process.