• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.675-681
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• 2002

Parametric modeling and configuration design method are a important methods for rapid design in manufacturing. This paper proposes a relation rules which parametrically models a bonnet trimming tool based on Pro/Engineer. The concept of desogn is applied a trimming die of the bonnet outer panel. Trimming die have a many parameters. Each a parameter is related the die face and punch profile. A design system consists of a Pro/Engineer, a Pro/program.

• 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.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.4
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• pp.29-38
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• 2003

This paper deals with an automated computer-aided process planning and die design system with which designer can determine operation sequences even after only a little experience in process planning and die design of multi former-bolt products by multi-stage former working. The approach is based on knowledge-based rules, and a process knowledge base consisting of design rules is built. Knowledge fur 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 AutoCAD with 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 four main 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 multi former, and the availability of standard parts. It 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 and the level of the required forming loads by controlling the forming ratios. The system uses 2D geometry recognition and is integrated with the technology of process planning, die design, and CAE analysis. The standardization of die parts for multi former-bolt products requiring a cold forging process is described. The system developed makes it possible to design and manufacture multi former-bolt products more efficiently.

• Design & Manufacturing
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• v.8 no.1
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• pp.35-39
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• 2014

Window roller housings are durable because high-quality source materials such as stainless steel is used in making them. After a series of precise structure analysis, their design is optimized. They are subject to repetitive driving tests of more 100,000 times, durability tests, impact resistance tests, corrosion tests and others. For a long time, gaps often occur in press molded products owing to serious squareness deformation and flatness deformation of them. Severe burrs in press molded products require frequent grinding, which leads to short life cycle and rough or unreliable movement of assembled roller housing, which, in turn, causes product defects. This study focuses on developing measures to resolve existing defects and to improve lifespan of dies by designing and making a window roller shearing die.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.10
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• pp.77-82
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• 2000

The design of the prestressed cold extrusion die with two stress rings has been performed in this study. The cold extrusion has been simulated by the rigid-plastic FEM. The stress analysis of die has been performed for both after shrink fitting and during extrusion by using the elastic FEM and the Lame's equation. According to the variation of interferences and diameter ratios, the maximum effective stress has been evaluated. As results, interferences and diameters were determined by the minimization of the maximum effective stress of die insert. The comparison of the maximum effective stress between the proposed design and the conventional design has been discussed. It was found that the maximum effective stress in the die insert is considerably affected by the stiffness of the first stress ring.

• Transactions of Materials Processing
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• v.19 no.3
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• pp.173-178
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• 2010

A die cast impeller blade has been developed in the effort on cost reduction in marine equipment industry. The purpose of this work is to optimize the die casting process using Taguchi's design of experiment for minimizing the internal defect of the die cast impeller blade. The experiments were preformed using the numerical simulation based on the L18 orthogonal array. As a results, the internal defect size of the die cast impeller blade for optimal design was controlled less than 1mm.

• 제어로봇시스템학회:학술대회논문집
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• 1988.10a
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• pp.556-561
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• 1988

Shrink-rings (Stress-rings) are used in the fabrication of dies for cold forming and powder compaction processes to increase the allowable pressures for a given die material. Optimum procedures are to minimize a die thickness under the conditions that the stress distributions in the die and stress-rings utilize fully the strength available in each of the die elements. This paper proposes a new approach, where the maximum allowable shrinking pressures are calculated on shrinkage plans in the radial direction and the fractional shrinking pressures below the maximum allowable pressures are used as the design values. Two criteria for the optimal die design are used: Maximum shear stress limit for one-piece dies and zero tensile stress limit for combined dies. A computer program, DIECOM, is developed for illustrating the computer-aided design procedures. Finally, examples for each case are presented in this paper.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.932-936
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• 1997

In order to increase the productivity of electrical parts, manufacturing processes using progressive die have been widely used in the industry. If closed-die forging process may be included in the series of the forming process, however, there arise many problems in the die design, such as determination of blank size, feeding method and formability, etc. For the proper design of a process, a prediction of the process is requred to obtain many design parameters. In this work, three-dimensional rigid-plastic finite element analysis is carried out to simulate precision forging process. The forging process of STEM, a part of photo pick-up hologram device, is simulated with the two types of processes, open die forging and semi-closed die forging, respectively. Form the results of analyses, the forging processes can be predicted successfully, which enables to design appropriately the die and the process.

• Transactions of Materials Processing
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• v.14 no.3 s.75
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• pp.239-244
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• 2005

The die & mould-design system fur the productivity increase is developed by our company. This system is made by UG API and constructs the standard through DB of parts of die & mould. Besides, the result of engineering analytic method is reflected in the design process in this system and the product precision is secured by On Machine Measurement method. Therefore, the ground of quality improvement and process innovation is solidified by the developed system and the competitiveness of die & mould manufacturing is intensified.

• Journal of Korea Foundry Society
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• v.28 no.4
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• pp.190-194
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• 2008

Thin-walled die casting of aluminum notebook computer housing with less than 1mm thickness was investigated by using computational solidification simulation and actual casting experiment. Three different types of gate design, finger, tangential and split type, were used and the results showed that sound thin-walled die casting was possible with tangential and split type gating design because those gates allowed aluminum melt flowed into the thin-wall cavity uniformly and split type gating system was preferable gating design than tangential type at the point of view of soundness of casting and distortion generated after solidification. Also, solidification simulation agreed well with the actual die-casting and the casting showed no casting defect and distortion.