Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Byun, Jong Bok; Razali, Mohd Kaswandee; Lee, Chang Ju; Seo, Il Dong; Chung, Wan‐Jin; Joun, Man Soo

doi:10.3390/ma13225300

Cited by 19 publications

(17 citation statements)

References 36 publications

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“…[90] Copyright 2008, Elsevier). Byun et al [98] suggested the use of nonisothermal analysis of temperature effect for automatic cold forging of SUS304 ball-stud as it gave positive results on die wear and its fatigue characteristics.…”

Section: Forging Toolsmentioning

confidence: 99%

A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

Sharma

Gupta

et al. 2023

steel research int.

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Forging is a primary manufacturing process used in several manufacturing industries. Aircraft and automobile industries are manufacturing products with high‐dimensional accuracy and quality that are highly precise or near the required shape. Customers require products that are free of cracks and fulfill their functional requirements. This leads to the advancement of the forging process due to its ability to form complicated and intricate shapes. Herein, a detailed review of the aspects of forging is given in which the optimization of factors like preform design, forging conditions, workpiece dimensions, die design, lubricant properties, and thermal treatment parameters are discussed, enhancing the tool life and forging quality of the product. The selection of die‐forging tool material and methods for enhancing the surface quality of forged products are also reviewed. The article also presents methods for measurement of forging quality, tool life, machine effectiveness, forging image acquisition, and forging parameters, which can significantly reduce the risk of error at every step of the forging process. This review serves as a reference for researchers to increase production rate, enhance the effectiveness of measurement system, and improve the quality of forged products with technological advancement.

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Section: Forging Toolsmentioning

confidence: 99%

A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

Sharma

Gupta

et al. 2023

steel research int.

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“…The implicit elastoplastic finite element method with tetrahedral MINI-elements [ 4 , 8 , 37 ] was used to simulate the process. We assumed that the material obeyed von Mises yield criterion while the die parts were assumed rigid in simulating the forging process.…”

Section: Characteristics Of Cyclic Stresses On a Prestressed Diementioning

confidence: 99%

“…To the contrary, the high-cycle fatigue (HCF) life of die parts is of great importance in cold forging [ 2 ], especially during automatic multi-stage cold forging. Die fatigue life is becoming a major issue because complicated die structural analysis has become increasingly possible owing to recent advances in metal forming simulation technologies [ 3 , 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

A New General Fatigue Limit Diagram and Its Application of Predicting Die Fatigue Life during Cold Forging

Joun

Chung

et al. 2022

Materials

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Traditional fatigue fracture theory and practice focus principally on structural design. It is thus too conservative and inappropriate when used to predict the high-cycle fatigue life of dies used for metal forming, especially cold forging. We propose a novel mean stress correction model and diagram to predict the high-cycle fatigue lives of cold forging dies, which focuses on the upper part of the equivalent fatigue strength curve. Considering the features of die materials characterized by high yield strength and low ductility, a straight line is assumed for the tensile yield line. To the contrary, a general curve is used to represent the fatigue strength. They are interpolated, based on the distance ratio, when finding an appropriate equivalent fatigue strength curve at the mean stress and stress amplitude between the line and curve. The approach is applied to a well-defined literature example to verify its validity and shed light on the characteristics of die fatigue life. The approach is also applied to practical forging and useful qualitative results are obtained.

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“…The strain up to which the flow stress was theoretically obtained was quite large. The technique can predict the flow stress at the strain of around 1.5, depending on the materials [ 33 , 34 , 35 ]. Note that the point marked “necking point” in the true stress-strain curve in Figure 6 corresponds to the actual necking point in Figure 7 .…”

Section: Problem Descriptionmentioning

confidence: 99%

A New Methodology for Predicting Brittle Fracture of Plastically Deformable Materials: Application to a Cold Shell Nosing Process

Eom¹,

Byun²,

Jeong³

et al. 2021

Materials

Self Cite

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The traditional theory of ductile fracture has limitations for predicting crack generation during a cold shell nosing process. Various damage criteria are employed to explain fracture and failure in the nose part of a cold shell. In this study, differences in microstructure among fractured materials and analysis of their surfaces indicated the occurrence of brittle fractures. The degree of “plastic deformation-induced embrittlement” (PDIE) of plastically deformable materials affects the likelihood of brittle fractures; PDIE can also decrease the strength in tension due to the Bauschinger effect. Two indicators of brittle fracture are presented, i.e., the critical value of PDIE and the allowable tensile strength (which in turn depends on the degree of PDIE or embrittlement-effective strain). When the maximum principal stress is greater than the latter and the PDIE is greater than the former, our method determines the likelihood of brittle fracture. This approach was applied to an actual cold shell nosing process, and the predictions were in good quantitative agreement with the experimental results.

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Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Cited by 19 publications

References 36 publications

A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

A Systematic Review of Factors Affecting the Process Parameters and Various Measurement Techniques in Forging Processes

A New General Fatigue Limit Diagram and Its Application of Predicting Die Fatigue Life during Cold Forging

A New Methodology for Predicting Brittle Fracture of Plastically Deformable Materials: Application to a Cold Shell Nosing Process

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