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:msjoun@gnu.ac.kr

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.