• Transactions of Materials Processing
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• v.12 no.6
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• pp.558-565
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• 2003

Rotary swaging is one of the incremental forming process which is a chipless metal forming process for the reduction of cross-sections of bars, tubes and wires. In the present work, the rotary swaging machine and dies were designed to investigate the formability of TDS(Tube Drive Shaft) used in automotive industry. The process variables such as the speed of forming, the shape of the formed materials and the reduction of area were also estimated to study experimental analyses of rotary swaging process using the materials of 34Mn5 and S45C. From experimental results, it was found that the process variables affected the quality of TDS in terms of hardness, the precision of products and the surface roughness. The hardness after swaging approved to be Increased with the increase in the reduction of diameter. And it was found that the grain size became smaller and the elongated grains were formed in the axis direction.

• Transactions of Materials Processing
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• v.25 no.5
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• pp.332-337
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• 2016

The automobile cowl cross bar which is a backbone frame part holding electrical and air conditioning components inside the cockpit module has been designed with more complex geometries recently due to demands of its enhanced functions and reduced weight of frame parts. The traditional manufacturing process using welding between tubes with different diameters shows several problems such as poor mechanical characteristics and appearance, etc. Therefore, in this study, one-piece manufacturing processes which can eliminate the welding process were developed by applying the rotary swaging process. CAE analyses were conducted to examine the feasibility of the process and prototypes were manufactured by using a rotary swaging machine with 4 split rotating dies and 12 head rollers. Bending tests of the manufactured prototypes confirmed that the rotary swaging process gives better mechanical properties comparing with the conventional processes.

• Journal of Power System Engineering
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• v.14 no.6
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• pp.54-60
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• 2010

The automotive air conditioning hose is used for connecting the components of air conditioner in a vehicle. The hose is usually manufactured by the swaging process to connect the rubber hose with the metal fitting at the end of the hose. The swaging process leads to various stress and strain configurations in the hose, which give a critical effect on the hose performance. In this paper, the deformation characteristics of an air-conditioning hose during the swaging process were analyzed using the nonlinear finite element method. Especially the rubber layers, which are contacted with the metal fittings, were divided with finer mesh density than the reinforcement braids to increase the solution accuracy. The material properties were obtained from experimental data, and the contact conditions were used in consideration of the real manufacturing process.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2001.11a
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• pp.433-438
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• 2001

This study is performed to evaluate hand-arm vibration syndrome(HA VS) of the workers in swaging process. Vibration measurement and assessment of human exposure are based on the international standard(ISO 5349). Triaxial acceleration of each operation and exposure time are measured to predict the periods before finger blanching, As results, it is found that acceleration is concerned with the diameter of pipes in swaging process, and also found that combined work is more harmful than a single operation.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.344-350
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• 2003

This Paper deals with the weight-lowering and the traits of NVH(Noise, Vibration and Harshness) by the development of tubular shaft replacing the existing solid Drive Shaft for the lighter and less-noisy automobiles. By the review of Swaging Process this study reveals the various forming traits of Swaging, one of the forming methods for tubular shafts. Furthermore, it showed the possibility of Drive Shaft manufacturing through designing & manufacturing of Swaging machine for tubular shaft, and the production ar analysis of the tubular shaft with the relevant process and tools. This study also shows that the forming by swaging not only makes the mass production of tubular Drive Shaft possible but also may be widely applied to other products with many advantages in review of dimensional precision, thickness change, hardness increase and surface roughness of the swaged products.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.8
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• pp.760-766
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• 2009

In the manufacturing process of HDD, ball swaging method is commonly used to joint the Head Gimbal Assembly(HGA) with the arm of the actuator. The hub on the HGA is placed into the hole of the actuator arm, and the hub and arm is bonded by the pressure of steel ball. The pressure for plastic deformation on the baseplate causes the undesirable deformation on HGA, such as tilting, flying height change of head. After obtaining the key parameters that have large sensitivity on the swaging process, the optimal shape of baseplate is proposed to increase the static performance during swaging process. Contribution of the proposed design for the swaging performance is verified by contact simulation with elasto-plastic deformation.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.6
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• pp.464-469
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• 2017

This study evaluated the displacements of a Cu bar in the Y-direction and the relationship between swaging pressures and total contact forces to increase the productivity of the rotor core swaging process. Elastic-plastic numerical analyses of four different Cu bar shapes were performed with a constant swaging pressure to evaluate the displacements of the Cu bar in the Y-direction and the contact force distributions at the contact surfaces during the swaging process. Based on the numerical analysis results, the following conclusions were obtained. First, a simplified 2-dimensional cyclic symmetric analysis model was developed for the numerical analysis of the rotor core swaging process. Second, the final displacements of the Cu bar in the Y-direction were nearly the same as the change of the Cu bar size at a constant swaging pressure. Third, a linear relationship between the swaging pressures and the total contact forces, the so called resistance forces, was suggested.

• Proceedings of the KSME Conference
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• 2001.06a
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• pp.692-697
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• 2001

It is necessary to analyze the mechanical behaviors of the power steering hose, which must play a proper role under severe operating conditions, in order to prepare a preventive measure fur contrary effects expected in unfavorable circumstances. In this paper, the stress and deformation characteristics of the hose components such as rubber, sleeve, nipple and reinforced braids during the swaging process, are analyzed using the finite element method. Contact conditions identical to the manufacturing process are taken into account, and the material properties based on experimental data are used in the analysis. Investigations into the mutual relations between the manufacturing conditions and the hose performances are done with respect to the jaw stroke on the basis of the stress and strain values of the hose components after swaging process.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.6
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• pp.672-678
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• 2020

Ogive parts of large-caliber ammunition in Korea are manufactured by the Press Nosing method, but this method has the disadvantage of requiring additional processes such as lubrication before and after the press process. This study proposes the possibility of applying the Swaging method to improve these shortcomings. A large-diameter shell body was manufactured in sub-scale and plastic working experiments using a swaging process were performed. We investigated whether plastic processing is possible up to 75 % of the diameter reduction rate that satisfies the final molding dimension, and whether the dimensions of the product produced by swaging molding are satisfactory as the hardness changes according to the diameter reduction rate and the increase in thickness. The test using the prototype confirmed that the hardness increased proportionally with the diameter reduction rate and by more than HV 335 at the reduction rate of 75 %. The material thickness variation tended to be similar to the theoretical calculated value, and the thickness increase rate was proportional to 65.4 % at the reduction rate of 75 %.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.10
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• pp.21-26
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• 2016

This study evaluates the magnitudes and distributions of contact tangential forces with the swaging depth of punch acting at the contact surfaces between a rotor core slot and a Cu bar during a sequential rotor core swaging process. The effects of the core slot shape on the magnitudes and distributions of the total contact forces were investigated to improve the productivity of the rotor core swaging process. Parametric elastic-plastic numerical analyses were performed using simplified two-dimensional cyclic symmetric plane strain models to evaluate the contact force distributions at the contact surfaces. The numerical analysis results show that the total contact tangential forces increased by about 55% with the adjacent Cu bar swaging process. The length of the core slot is a dominant factor in the core slot design as result of the increased total contact tangential forces during the swaging process of the rotor core.