• Title/Summary/Keyword: drive-in process

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Forming Process of the Automotive TDS (Tube Drive Shaft) by the Rotary Swaging Process (자동차용 중공드라이브 샤프트의 성형공정 연구)

  • 임성주;이낙규;오태원;이지환
    • 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.

Plate Forging Process Design for an Under-drive Brake Piston in Automatic Transmission (자동변속기용 언더드라이브 브레이크 피스톤의 판 단조공정 개선 방안)

  • Jeon, H.W.;Yoon, J.H.;Lee, J.H.;Kim, B.M.
    • Transactions of Materials Processing
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    • v.23 no.2
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    • pp.88-94
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    • 2014
  • The under-drive brake piston is an essential part in the automatic transmissions of automobiles. This component is manufactured by forging after blanking from S55C plate with a thickness of 6mm. It is difficult to design the plate forging process using a thick plate approach since there will be limited material flow as well as large press loads. Furthermore, the under-drive brake piston has a complex shape with a right angle step, which often results in die unfill and abrupt increase in press load. To overcome these obstacles, a separate die for filling material sufficiently to the corner of the right angle step is proposed. However, this approach induces an uncontrolled workpiece surface between the dies, resulting in flash. This excess flash degrades the tool life in the final machining after cold forging as well as increases the cycle time to obtain the net-shape of the part. In the current study, we propose an optimum process design using a conventional die shaped with the benefit of finite element analysis. This approach enhanced the process efficiency without sacrificing the dimensional accuracy in the forged part. As the result, the optimum plate forging process was done with a two stage die, which reduces weight of by 6% compared with previous process for the under-drive brake piston.

Application of Press Quenching Technology to Automotive Drive Plate (프레스 퀜칭에 의한 자동차 드라이브 플레이트 제조에 관한 연구)

  • Jeong, W.C.
    • Transactions of Materials Processing
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    • v.20 no.8
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    • pp.588-594
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    • 2011
  • A new manufacturing process is presented for automotive drive plate using a boron-containing carbon steel sheet, which is hot-formed and press quenched. Particular attention was given to the capability of the process in minimizing dimensional change.

A study on improvement of manufacturing process of aluminum chassis drive gear (알루미늄 섀시 드라이브 기어 제조공정 개선에 관한 연구)

  • Lee, Chun-Kyu;Choi, Kye-Kwang
    • Design & Manufacturing
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    • v.12 no.1
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    • pp.26-30
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    • 2018
  • The aluminum chassis drive gear manufacturing process improvement has been very effective in both technical and economic aspects. Technology for Shear mold design technology, mold material selection and processing technology, and press molding technology has improved greatly overall. In the meantime, it is necessary to clarify the causes of defects that occur frequently due to lack of technology, Based on this, it is meaningful that it has secured the ability to respond to new product development and molding in the future. By applying these technologies, we plan to expand not only the drive gear chassis, but also various types of press forming such as frame, handle, various fastening parts of system window. In addition, the ability to develop precision products in the future is expected to become a driving force in further enhancing the competitiveness of companies.

Estimation of Conditions of Incremental Hot Rotary Forging Process for Monobloc Tubular Drive Shaft (일체형 중공 드라이브 샤프트 제작을 위한 점진적 열간 로터리 단조 공정 조건 예측)

  • Lee, Ho-Jin;Guk, Dae-Sun;Ahn, Dong-Gyu;Jung, Jong-Hoon;Seol, Sang-Suk
    • Journal of the Korean Society for Precision Engineering
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    • v.33 no.4
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    • pp.287-293
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    • 2016
  • A monobloc tubular drive shaft is designed to obtain the improved structural safety and the weight reduction of the drive shaft together. The monobloc tubular drive shaft can be manufactured from an incremental hot rotary forging process. The aim of this study was to experimentally determine conditions of an incremental hot rotary forging process for a monobloc tubular drive shaft. Induction heating experiments were performed to estimate a proper heating time of an initial workpiece in an induction heating process. Several incremental hot rotary forging experiments were carried out using a mechanical press with the designed set-up. The step distance and the step angle were chosen as controllable forming parameters. Based on the results of the experiments, the influence of forming parameters on the quality of the forged part was investigated. Finally, a forming map and a proper forming condition of the incremental hot rotary forging process were estimated.

A Study on the Rotary Swaging Machine and Process Development of Automotive Tubular Drive Shaft (자동차용 중공 구동축 성형장치 개발 및 성형공정에 관한 연구)

  • 오태원;유택인;현동훈
    • 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.

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A Study for the high speed motor drive system using DSP (DSP를 이용한 초고속 전동기 구동시스템에 관한 연구)

  • 권종혁;안재황;백동기;성세진
    • Proceedings of the KIPE Conference
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    • 1997.07a
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    • pp.436-440
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    • 1997
  • Recently the needs the interest for the high speed motor drive system is increased in many different fields. So in this paper, the high speed motor drive system is proposed to drive the high speed motor using DSP which was developed in order to process datas at high speed. The motor drive is performed using a variable V/f PWM control.

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Integrated Design of High-speed Feed Drive Systems (고속 이송계의 통합설계)

  • Kim, Min-Soek;Chung, Sung-Chong
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.27 no.12
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    • pp.2028-2038
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    • 2003
  • High-speed feed drive systems have been widely used in the manufacturing and semiconductor industries. Specifications for high-speed systems require more advanced capabilities than conventional feed drive systems. It is necessary to devise special design concepts to achieve the level of performance for high-speed feed drive systems. In this paper, an integrated design method is proposed for high-speed feed drive systems in which the interactions between mechanical and electrical subsystems ought to be considered simultaneously during the design process. Based on the integrated design method, a nonlinear optimal design procedure of mechanical subsystems considering the Abbe and radius errors is accomplished through the design process of electrical subsystems satisfying the control stability and the saturation condition of actuators as well as the relative stability. Both mechanical and electrical parameters are considered as design variables. Simulations and numerical case studies show that the integrated design method of high-speed feed drive systems creates results satisfying the desired performances of mechatronic systems.

Optimization of Drive-in Process with Various Times and Temperatures in Crystalline Silicon Solar Cell Fabrication (결정질 실리콘 태양전지 도핑 확산 공정에서 시간과 온도 변화에 의한 Drive-in 공정 연구)

  • Lee, Hee-Jun;Choi, Sung-Jin;Myoung, Jae-Min;Song, Hee-Eun;Yu, Gwon-Jong
    • 한국태양에너지학회:학술대회논문집
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    • 2011.11a
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    • pp.51-55
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    • 2011
  • In this paper, the optimized doping condition of crystalline silicon solar cells with 156 ${\times}$ 156 mm2 area was studied. To optimize the drive-in condition in the doping process, the other conditions except drive-in temperature and time were fixed. After etching 7 ${\mu}m$ of the surface to form the pyramidal structure, the silicon nitride deposited by the PECVD had 75~80 nm thickness and 2 to 2.1 for a refractive index. The silver and aluminium electrodes for front and back sheet, respectively, were formed by screen-printing method, followed by firing in $400-425-450-550-850^{\circ}C$ five-zone temperature conditions to make the ohmic contact. Drive-in temperature was changed in range of $828^{\circ}C$ to $860^{\circ}C$ and time was from 3 min to 40 min. The sheet resistance of wafer was fixed to avoid its effect on solar cell. The solar cell fabricated with various conditions showed the similar conversion efficiency of 17.4%. This experimental result showed the drive-in temperatures and times little influence on solar cell characteristics.

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Case of Integrated tolerance design process by Engineering tolerance design and 6 Sigma Tolerance Design - Spindle Motor For Optical Disc Drive - (공학공차설계와 6시그마 공차설계를 통합한 공차설계 적용 사례 - 광학 디스크 드라이브 스핀들 모터 -)

  • Kim, Yongtae;Ree, Sangbok
    • Journal of Korean Society for Quality Management
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    • v.42 no.4
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    • pp.563-578
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    • 2014
  • Purpose: The purpose of this paper is integrated tolerance design process by advantages of engineering design and 6 sigma statistical tolerances design. Methods: Integrated tolerance design process can determine the goals by using engineer's experience and clarify tolerance by 6 Sigma statistical methods. Integrated design process can be applied by using non-linear simulations. Results: We applied integrated design process to the optical disc drive spindle motor and get good result. Conclusion: If this method is applied test method in the early stages of development, then Design can be reduced development time and cost.