• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.84-88
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• 2003

In this paper, The optimum design of a die shape has been carried out the FEM analysis of a pilger mill process considering various factors. The pilger mill forming process consists of a pair of rotating die which has appropriate surface shape. The important design parameters of the pilger mill are the feed rate and the profile of grooved die. Optimum design procedure was performed in order to investigated effects on the forming load and the deformed shape of material depending on the die radius profile. Profile of the die surface for the optimum design were suggested with the linear, the cosine and the quadratic curve considering a physical forming process. The surface of each die was modeled using the 3DAutoCAD and the analysis of pilger forming process was performed using the LS-DYNA3D. The optimum profile of the die shape for the pilger mill was determined to the quadratic profile. Since the analysis results provide that the model of the quadratic profile gives the lowest forming load and a proper deformed shape.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.214-218
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• 1995

Much labor, an exceedingly long lead time, and the skills of experienced engineers are required for press tool design. To reduce such problems, several CAD systems for blanking or piercing have been developed. This paper describes a computer-aided design for blanking or piercing of irregularly shaped sheet metal products. An approach to the system is based on knowledge base rules. The process planning & die design system is designed by considering several factors, such as complexity of blank geometry, punch profile, and availability of press equipment and standard parts. Therefore, after checking a production feasibility for irregular shaped sheet metal products, this system which is implemented strip layout module can carry out a process planning and generate the strip layout in graphic forms. Also this system implemented die layout module can carry out a die design for each process which is obtained form the result of an automated process planning and generate parts and assembly drawing of a die set.

• Design & Manufacturing
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• v.7 no.1
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• pp.11-18
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• 2013

This paper presents the plastic inhomogeneous deformation behavior of bimetal composite rods during the axisymmetric and steady-state extrusion process through a conical die. The rigid-plastic FE model considering frictional contact problem was used to analyze the co-extrusion process with material combinations of Cu/Al. Different cases of initial geometry shape for composite material were simulated under different conditions of co-extrusion process, which includes the interference and frictional conditions. The main design parameters influencing on deformation pattern are diameter ratio of the composite components and semi-die angle. Efforts are focused on the deformation patterns, velocity gradient, predicted forming load and the end distance through the various simulations. Simulation results indicate that there is an obvious difference of forming pattern with various diameter ratio and semi-die angle. The analysis in this paper is concentrated on the evaluation of the design parameters on the deformation pattern of composite rod.

• Transactions of Materials Processing
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• v.10 no.5
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• pp.373-382
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• 2001

Die design by computer simulation has some advantages compared with the conventional method which has performed by designer's experiences and trials and errors. The die filling and solidification process of thixoforming process were simulated by MAGMAsoft/thixo module. Furthermore, the die design for thixoforming was performed with the various geometry shape. The effect of designed gate dimension on filling phenomenon was estimated by filling simulation. The calculated results was compared with experimental data. The free surface phenomenon obtained by experiment have good agreement with computer simulation results. The solidification effect much as prosity and shrinkage for designed semi-solid forging die had been predicted by computer simulation. The designed die for semi-solid forging had been applied to produce of the frame part which is used to airconditious system.

• Transactions of the Korean Society of Mechanical Engineers
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• v.12 no.4
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• pp.712-720
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• 1988

This paper describes some development of computer-aided system called "COLD-FORMING" and "DESIGN-DIE". "COLD-FORMING" is designed for the forming sequence and "DESIGN-DIE" for the die design of press forming rotationally symmetric parts. The computer program developed is used in interactive and written in BASIC. Design rules for process planning and die design are formulated from process limitations, plasticity theory and know-how of experience of the field. "COLD-FORMING" capabilities include (1) analysis of forming sequence and recognition of individual operation involved each step, (2) determination of intermediate shape and dimensions, (3) calculation of forming loads to perform each forming operation and (4) graphic out put for the operation sheet. "DESIGN-DIE" capabilities include (1) optimum die design corresponding to the output of "COLD-FORMING" and (2) graphic output for the die design.of "COLD-FORMING" and (2) graphic output for the die design.ie design.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.5
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• pp.22-33
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• 1997

This paper describes a research work of developing a computer-aided design of blanking and piercing for stator and rotor parts. Based on knowledge-based rules, the die design system, STRTDES2, is designed by considering several factors, such as complexities of blank geometry and punch profile, and availability of press equipment and standard parts. Therefore this system can carry out a die design for each process which is obtained from the result of an automated process planning system, STRTDES1 and generate part drawing and the assembly drawing of die set in graphic forms. Knowledges for die layout are extracted from plasticity theories, relevant references and empirical know-hows of experts in blanking industries.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.2
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• pp.45-51
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• 2003

The multi-piloting type progressive die for U-bending sheet metal production part is a very specific division. This study reveals the sheet metal forming process with multi-forming die by center carrier type feeding system. Through the FEM simulation by DEFORM, it was accepted to u-bending process as the first performance to design of strip process layout. The next process of die development was studied according to sequence of die development, i.e die structure, machining condition for die making, die materials, heat treatment of partially die components, know-how and so on. The feature of this study is the die development of scrapless progressive die of multi-stage through the modeling on the I-DEAS program, components drawing on the Auto-LISP, CAD/CAM application, ordinary machine tool operating and revision by tryout.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.126-129
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• 2008

This paper concerns the progressive die design for an automotive bracket part aided by the computer simulation in order to eliminate the inferiority such as the crack. The computer simulation of the progressive forming process is utilized in order to investigate cause of the cracks. This paper proposes a new guideline for the die design which modifies intermediate shapes and adds intermediate forming stages in progressive forming process. The effectiveness of the proposed design is verified by the computer simulation. The simulation result shows that the modified die design for the progressive forming process can eliminate the crack and improve quality of the automotive bracket part.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.75-80
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• 2008

The progressive die performs a work of sheet metal processes with a piercing, notching, embossing, bending, drawing, cut-off etc. in many kinds of pressing. Now a days, these processes have been evaluated as a advanced tooling method to increase the productivity and high quality assurance. The first step analyzing of die design is production part review, then the arrangement drawing of product design and strip process layout design should be done as a next steps with a FEM simulation for its problem solution. After upper procedure were peformed, it was started to make the die, then tryout and its revision of the die and product quality, safety, productivity etc. were done continually. For the all of these process, we mobilized the theory and practice of sheet metal forming, die structure, the function and activity of die components, and the others of die machining, die material, heat treatment and know‐how so on. In this study the features of representative are production part analyzing through the FEM simulation of bending area with a considering spring back problem by DEFORM.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.95-98
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• 1999

In this study, a method to find the optimal intermediate die geometry for the multi-stage drawing process for the rectangular rod from a round bar is proposed and a program using the proposed method is developed. On the stage of the design of the intermediate die geometry, the virtual die was constructed using the initial billet as a inlet of the drawing die and the final product as a exit of that and the virtual die was divided by the number of pass. Divided die was transformed into the rectangular one which is the intermediate die geometry for the multi-stage rectangular drawing process. In order to verify the application of the proposed method on the real industrial product, the drawing of the rectangular rod from a round which composed two stage has been performed and simulated by the three dimensional rigid plastic finite element method.