2011. 11. 11 the korean society of manufacturing...
TRANSCRIPT
소성가공이 기계가공산업에 미치는 영향에 관한 사례 연구
www.afdex.com
AFDEX
2011. 11. 11
The Korean Society of Manufacturing process Engineers
* # 전만수1) ,김민철1), 엄재근 1), 전병윤2)
1) 경상대학교 기계공학부
2) 진엔지니어링
#) 경상대학교 기계공학부/공학연구원
E-mail:[email protected]
Contents
⊙ Introduction to TIC of Gyeongsang National University
⊙ Introduction to intelligent metal forming simulator, AFDEX
⊙ Case studies of cooperation between metal forming and machining
⊙ Case studies of competition between metal forming and machining
⊙ Conclusions
5/20
경상대 TIC 특화 분야별 구축 장비
⊙ 수출용 베벨기어 개발(우성정공, 진ENG)
• 설계 및 엔지니어링, 제조기술 국제
경쟁력 확보
• 일본으로부터 100여종의 베벨기어 수주
○ 수출용 베벨기어 수주 및 개발 실적 ○ CAM 및 정밀 금형 가공 ○ 시험생산
○ 주요 실적
○ 베벨기어 단조 공정 설계 기술
기업체 성공사례 I
⊙ 신제품 – 분말 성형 및 분말 사출 (세타택)
○ 전국 최고의 분말 성형 관련 엔지니어링 그룹으로 구성 (박사급 2명)
○ CAE 기술 기반 분말사출성형(PIM)과 분말야금(PM) 기술을 이용한 부품(의료, 방산, 전자, 기계) 개발 및 제조
○ 특허 15건 등록, 프로그램 등록 7건
신제품
S/W
<방산용 분말야금 및 사출성형품>
<의료용 분말사출성형품>
<전자기기 분배관 분말사출성형품>
기업체 성공사례 II
AFDEX
www.afdex.com
Intelligent metal forming simulation
using AFDEX, a general purpose intelligent metal forming simulator
○ Material: SWCH10A
○ DCr=1.68
A
C B
12.5slope
0.002
12.5slope
0.002
Fracture prediction in tensile test
O
Elongation [mm]
Te
nsi
lelo
ad
[kN
]
0 1 2 3 4 5 6 7 8 90
2
4
6
8
10
12
ExperimentPrediction
A
C
B
O
B
C
O A B
Verification of predictions
PredictionExperiment
SCM435 ESW105
Non-contacted Contacted Non-contacted Contacted
Accuracy – Cold forging, automobile part
KSME Spring 2006
Trans. ASME J. Eng. Mat. Tech. 1998 / Int. J. Mach Tools Manuf. 2000 / Trans. ASME J. Eng. Mat. Tech. 2007.
Metal flow and
temperature
Damage
Internal crack
Accuracy – Hot forging, bearing race
Accuracy – Enclosed die forging, bevel gear
Enclosed die forging Sizing
Accuracy – Hammer forging, ship engine part
KSPT Spring 2009
Applicability – Applications of the year 2008
Applicability – Applications of the year 2009
⊙ Metal formed products are more reliable in strength than machined parts
⊙ Mileage is dependent on the weight of cars, i.e., 1kph / 100kg
⊙ Material is the concentrated energy
⊙ Green manufacturing is a megatrend
Introduction
Enclosed die forging
Slider
Bolster
Upper
punch
Lower
punch
Upper
die
Lower
die
CL
CL
CL
WorkPiece
Bevel gear
Inner race
Tripod Long shaft bevel gear
Enclosed die forging
Cold former forging
Thread rolling
Metal Forming 2010
Microforming
5.3mm
3.7
mm
0.7mm
0.9mm
Tearing roller
Lower die Workpiece
Forming roller
Upper die
Chipless forming (flow forming)
Proposed method 1 of making spindle
Proposed method 2 of making spindle
Pass 1
Pass 2
Pass 3
Radial forging
Train axle shaft
Round rod radial forging
Train axle shaft
Ring rolling
Cold profile ring rolling
Hot profile ring rolling
Wind tower flange
ring rolling
Finishing metal forming after machining
Tilted face defect predication
Conclusions
⊙ Competitive and cooperative areas and topics between metal forming
and machining are introduced with typical application examples.
⊙ Importance of cooperative research is emphasized to reduce
manufacturing costs of mechanical parts and to save the
environments with minimum use of materials.