Calculation of kinetic locus of upper tool in cold orbital forging machine with two eccentricity rings

Xinghui Han,Xinchang Zhang,Lin Hua 대한기계학회 2015 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.29 No.10

In cold orbital forging machine with two eccentricity rings, the kinetic locus of the upper tool includes two types. The first one is thekinetic locus of one point in the axis of the upper tool, which is produced by the motion of the two eccentricity rings. The second one isthe kinetic locus of one point in the working surface of the upper tool, which is produced by the first type of kinetic locus. Both types ofkinetic locus of the upper tool is critical to cold orbital forging. The first one has great influences on the deformation of cold orbitalforged components and the second one can be used to make the intervention examination between the upper tool and components. So thispaper aims at obtaining the kinetic locus of the upper tool in cold orbital forging machine with two eccentricity rings so as to better designand check the cold orbital forging tools. Firstly, a model of analyzing the kinetic locus of the upper tool is developed. Then, the generalequations of the kinetic locus of the upper tool, which can describe the kinetic locus of the arbitrary point in the upper tool under allkinds of geometric and kinematic relations between the two eccentricity rings in cold orbital forging machine, are achieved. Finally, thecharacteristics and applications of the kinetic locus of the upper tool are discussed based on these equations. This study has great significancesfor adjusting the two eccentricity rings of the machine to control the motion of the upper tool and designing and checking the coldorbital forging tools.

정밀냉간단조 기술을 적용한 자동차 액추에이터용 스퍼기어 부품개발

박동환,한성철 한국소성∙가공학회 2023 소성가공 : 한국소성가공학회지 Vol.32 No.6

Spur Gear parts for automobile actuators using existing former forging technology were produced in a total of three processes on a former forging machine. However, in order to improve cost increase due to frequent mold breakage, Spur Gear parts were designed and manufactured in the cold forging process after forming the preform through former forging. In other words, in the existing former forging mold, product seating defects occurred due to horizontal movement, resulting in many product defects and mold damage, so there was an urgent need to improve mold life and product defects. In order to improve this, we tried to improve the mold life by improving the existing 3 former forging processes to a former forging process and 2 cold forging processes. Therefore, We developed Spur Gear parts for automobile actuators were developed by applying precision cold forging technology through a former forging process and 2 cold forging processes to improve mold life.

전자식 파킹 브레이크용 세레이션 기어의 냉간다단단조 공정 설계 및 후방 압출특성에 관한 평가

서주한(Ju-Han Seo),최종원(Jong-Won Choi),정의은(Eu-Enn Jung),강명창(Myungchang Kang) 한국기계가공학회 2022 한국기계가공학회지 Vol.21 No.2

Reducing production costs through net-shaped cold forging is an important aspect in the automobile industry. In this study, we intend to produce a net-shaped electronic parking brake (EPB) serration gear for automobiles, using multi-stage cold forging. These serrations are then assembled to the reduction gear of an EPB actuator. The forging process of the serrations and the cold forging design were verified through finite element analysis (FEA) in order to evaluate metal flow. The forging machine was selected by checking the load using FEA. Based on the FEA results, molds were designed, and parts were made using multi-stage cold forging to produce a net-shaped serration gear.

Compensation of springback error based on comprehensive displacement method in cold rotary forging for hypoid gear

Yugong Dang,Yongyu Yao,Xiaozhong Deng,Genggeng Li,Chuang Jiang 대한기계학회 2019 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.33 No.7

Special cold rotary forging method for the fabrication of the big wheels of hypoid gears is proposed. The proposed method is established on the basis of the requirements of antifatigue manufacturing processes and the tooth profile characteristics of hypoid gears combined with the movement and forming methods of cold rotary forging. The geometric grid model is constructed on the basis of the basic theory of elastic-plastic thermo-mechanical coupling finite element for metal. Reasonable process parameters and boundary conditions are established. Thus, the cold rotary forging finite element model is built. The springback tooth surface is reconstructed through the results of finite element numerical simulation. The size and distribution of the springback error is the detected. In the springback process, a large displacement and large rotation can occur, so a comprehensive displacement compensation algorithm is adopted to modify the rotary forging die, and a springback error compensation iteration system is constructed based on the modified algorithm. In the case of a camion driving axle gear, the correction of the rotary forging die is analyzed. Results show that the error is already within the allowed range through only three iterations, which proves the efficiency of the system. The modified die is used for machining experiments. The measurement results of the experiment gear are consistent with the simulation results, which proves the reliability of the system. The LTCA of the gear further proves its reliability in compensating for springback error using numerical simulation technique.

Process design of multi-stage cold forging with small size for ESC solenoid valve parts

Hak-Sun Lee,Sang-Gyun Park,홍명표,Young Suk Kim 대한기계학회 2022 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.36 No.1

ESC’s solenoid valves independently brake each wheel, allowing the vehicle to maintain braking and directional stability. The most important component of the solenoid valve is the armature manufactured by the turning process by a CNC lathe so far. In this study, we propose to use the multi-stage cold forging process as an alternative to reduce manufacturing cost while satisfying dimensional accuracy and performance. To apply the multi-stage cold forging process, the whole forming process is divided into six stages to improve the dimensional accuracy of the outer diameter, full length and slot part of the armature. It is divided into 6 stages, but 6 stages are operated simultaneously in one stroke of forging. Inducing uniform plastic deformation by designing the preform for each stage of the armature slot. Through the proposed process design for the multi-stage cold forging process, the dimensional accuracy of the test product can be improved. The weight of the input material in the turning process can be reduced by 46 % from 3.5 g to 1.9 g by applying the multi-stage cold forging process. In addition, the manufacturing process can be reduced from 2 processes to 1 process, and the production quantity can be increased by 2500 % from 180 ea to 4800 ea per hour.

중공형 단조품 성형 공정 설계

권용남(Young-Nam Kwon),김상현(S. H. Kim),김상우(S. W. Kim),구본규(Bo Kyu Gu) 한국소성가공학회 2012 한국소성가공학회 학술대회 논문집 Vol.2012 No.5

A cold forging process for hollow shaft shape was designed by using finite element method in the present study. Hollow shaft products have been widely used for auto transmission parts and other applications. Hollow shaft has been usually fabricated with gun drill machining to lower the weight of final product. However, more cost efficient ways to manufacture hollow type product has been sought since conventional machining usually costs quite much. There have been several ways to make hollow type forgings such as rotary swaging and rotary forging, which cost a lot of initial machine cost. In the present study, a conventional cold forging process was designed to make hollow shaft product using several step forgings.

냉열간 단조기술을 적용한 농기계용 클러치 Jaw 부품 일체화 성형기술

박동환(Dong-Hwan Park),한성철(Seong-Chul Han) 한국생산제조학회 2015 한국생산제조학회지 Vol.24 No.5

Forging is a manufacturing process involving the shaping of metal using localized compressive forces and the process of deforming metal into a predetermined shape using certain tools and press according to the temperature. Forging provides stronger metal parts than that possible by casting or machining. Conventional clutch jaw parts have been developed through cold forging and precision machining; however, fabrication of integral clutch jaw parts for farm machinery has not been reported yet. These parts were developed by applying a complex forging technology combining cold and hot forging. The integrated forming technology proposed in this study will be useful for reducing the lead-time for manufacturing, improving the accuracy of products, and eliminating the welding process.

중공단조품 냉간단조공정 설계

권용남(Yong-Nam Kwon),김상우(S. W. Kim),구본규(B.G.Gu) 한국소성가공학회 2010 한국소성가공학회 학술대회 논문집 Vol.2010 No.5

A cold forging process for hollow shaft shape was designed by using finite element method in the present study. Hollow shaft products have been widely used for auto transmission parts and other applications. Hollow shaft has been usually fabricated with gun drill machining to lower the weight of final product. However, more cost efficient ways to manufacture hollow type product has been sought since conventional machining usually costs quite much. There have been several ways to make hollow type forgings such as rotary swaging and rotary forging, which cost a lot of initial machine cost. In the present study, a conventional cold forging process was designed to make hollow shaft product using several step forgings.

냉간단조를 이용한 중공형 부품 제조공정 개발

권용남(Yong-Nam Kwon),김다영(Da Young Kim),구본규(Bo Kyu Gu) 한국소성가공학회 2011 한국소성가공학회 학술대회 논문집 Vol.2011 No.5

A cold forging process for hollow shaft shape was designed by using finite element method in the present study. Hollow shaft products have been widely used for auto transmission parts and other applications. Hollow shaft has been usually fabricated with gun drill machining to lower the weight of final product. However, more cost efficient ways to manufacture hollow type product has been sought since conventional machining usually costs quite much. There have been several ways to make hollow type forgings such as rotary swaging and rotary forging, which cost a lot of initial machine cost. In the present study, a conventional cold forging process was designed to make hollow shaft product using several step forgings.

금형 탄성변형을 고려한 베벨기어의 탄소성 유한요소해석

정석환(S. H. Chung),정완진(W. J. Chung),전만수(M. S. Joun) 한국소성가공학회 2016 한국소성가공학회 학술대회 논문집 Vol.2016 No.4

In this paper, elastoplastic finite element analysis of a bevel gear cold forging process is conducted with emphasis on elastic deformation of dies to reveal on the importance of precision forging simulation for net-shape forging. Springback analysis is also carried out to predict final shape of forging with high accuracy. The predictions obtained with elastic deformation of dies considered are compared with those obtained.