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玻璃升降器复合拉深模的设计,玻璃,升降,复合,拉深模,设计
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Journal of Materials Processing Technology 139 (2003) 422427New processes to prevent a flow defect in the combinedforwardbackward cold extrusion of a piston-pinD.J. Leea, D.J. Kimb, B.M. Kimc,aDepartment of Precision Mechanical Engineering, Graduate School, Pusan National University, Pusan, South KoreabDepartment of Mechanical Design Engineering, Graduate School, Pusan National University, Pusan, South KoreacDepartment of Mechanical Engineering, Engineering Research Center for Net Shape and Die Manufacturing, Pusan National University, No. 3,Janjeon-Dong, Kumjeong-Ku, Pusan 609-735, South KoreaAbstractA flow defect of a piston-pin for automobile parts are investigated in this study. In the combined cold extrusion of a piston-pin, a lappingdefect,whichisakindofflowdefect,appearsbythedeadmetalzone.Thisdefectisevidentinproductswithasmallthicknesstobepiercedand is detrimental to dimensional accuracy and decrease of material loss. The flow defect that occurs in the piston-pin has bad effects onthe strength and the fatigue life of the piston-pin. Therefore, it is important to predict and prevent the defect in the early stage of processdesign. The best method that can prevent the flow defect is removing or reducing dead metal zone through the control of material flow.Finite element simulations are applied to analyze the flow defect. This study proposes new processes which can prevent the flow defect byremoving the dead metal zone. Then the results are compared with the results of experiments for verification. These FE simulation resultsare in good agreement with the experimental results. 2003 Elsevier Science B.V. All rights reserved.Keywords: Flow defect; Piston-pin; Material flow control; Forwardbackward extrusion; Dead metal zone; FE simulation1. IntroductionCold forming is extremely important and economical pro-cesses, especially for producing parts in large quantities.Because of advantages of cold forming such as high pro-duction rates, excellent dimensional tolerances and surfacefinish, mechanical and metallurgical properties, cold form-ing is by far the largest application of industry for producingparts.However, cold forged parts are also used in manufactur-ing aircraft, motorcycles, nuts and bolts 1, but it is possiblefor defects to occur in forged parts, depending on the de-formation history, forming conditions and material flow pat-tern, etc. The kind of defects are ductile fracture caused bythe state of stress and the deformation history, flow defectscaused by unstable material flow, and poor dimensional tol-erances caused by inferiority of the die and friction condi-tion. Further, defects in forged parts are classified as internaldefects and external defects 24.These defects have harmful effects on the quality of theproduct and an increase in the cost of production. Therefore,Corresponding author. Tel.: +82-51-510-3074; fax: +82-51-514-7640.E-mail address: bmkimpusan.ac.kr (B.M. Kim).it is important to predict and prevent defects in the earlystage of process design.Wifiet al. 5 studied ductile fracture in bulk formedparts, using different workability criteria by the finite ele-ment method. Kim and Kim 6 studied internal and exter-nal defects of cold extruded products with double ribs andperformed process design to prevent these defects.In this study is examined a defect which occurs in produc-ing a forwardbackward extrusion product, a piston-pin foran automobile part, and new processes are designed to pre-vent the defect by finite element method in the early stageof process design. Then the results are compared with theresults of experiments for verification.2. Forming and defect-occurrence analysis2.1. Forming processThe piston-pin is an automobile components used in thetransmission of power between the connecting rod and thecrankshaft. In the cold extrusion of a piston-pin, the designrequirements are to keep the same height of the forwardextruded part and the backward part (Fig. 1) without anydefect in the forged product, for use under high and repeated0924-0136/03/$ see front matter 2003 Elsevier Science B.V. All rights reserved.doi:10.1016/S0924-0136(03)00515-6D.J. Lee et al./Journal of Materials Processing Technology 139 (2003) 422427423Fig. 1. Shape and dimension of the piston-pin.Fig. 2. Photograph of a flow defect of a piston-pin.load. The material used for the piston-pin is AISI-4135H(Fig. 2) alloy steel, with the following flow stress behavior: = 768.06 0.139(MPa)Fig. 4. Distribution of effective strain and fracture value.Fig. 3. Conventional forming process for a piston-pin.The lubricant used is phosphate coating and bond lube. Thefriction factor, m, is assumed to be 0.1, which is confirmedby the ring compression test.The sequence of the conventional process for thepiston-pin is performed using a multi-stage former (Fig. 3).The first and second stages are pre-upsetting to eliminatedefects by the cropping process such as ovality and ec-centricity of the billet for improvement of dimensionaltolerances and die life whilst the third and forth stages areforward or backward extrusion for the forming of one di-rection from the web, and final stage is the piercing processfor the pin shape.However, the results of experiment for the conventionalprocessdisplayedadefectinthewebpartformedearlyinthethird process (Fig. 3). Especially, a nonuniform flow patternis observed in part of the defect occurrence, which lookslike a flow defect similar to lapping with an undesirable flowpattern.2.2. Prediction of defects by FE analysisDEFORM is used, which is commercial code of arigid-plastic FE program for forming and defect analy-sis. The diameter of the initial billet is 30mm and theheight is 61mm, the whole volume of final product being424D.J. Lee et al./Journal of Materials Processing Technology 139 (2003) 422427Fig. 5. Metal flow and velocity distribution, where a defect occurs according to stroke.43,118mm3. The forming is simulated with a conventionalprocess sequence.The maximum fracture value that can estimate the occur-rence of a crack 7 is small at 0.08 and is distributed ina position within the head part of the punch, so that a de-fect does not occur. Thus this defect is not one due to duc-tile fracture (Fig. 4). Then flow line-tracking scheme thatwas proposed by Altan and Knoerr 8 is performed for de-fect analysis. According to the progress of the punch stroke,severe variation of flow lines appears and discontinuity ofvelocity occurs in the part that a defect occurred in the ex-periment (Fig. 5).Consequently, the metal flows only in the backward di-rection without flow to the forward direction in the fourthprocess and metal near the web part is pulled up in the ribpart like a lapping defect. Therefore, the cause of the ini-tiation and development of the flow defect that occurred inpiston-pin is the velocity discontinuity between backwardand forward direction by the formation of a dead metalzone. This appearance evidently occurs in products like apiston-pin with a low thickness to be pierced for the dimen-sional accuracy and the decrease of material loss. A flowdefect occurring in a piston-pin has harmful effects on thestrength and the fatigue life of a piston-pin that has high andrepeated load at high temperature. Therefore, it is necessaryfor a new process to prevent the flow defect.3. Process redesign and analysis for the preventionof defectThe cause of the initiation and development of the flowdefect is the restriction of metal flow by the dead metalzone. For the elimination of the dead metal zone in theearly extruded part (3rd process) in the conventional process,the forward or backward extrusion process is modified tocombined forwardbackward extrusion, which is performedsimultaneously in the two directions. Because of the varietyof extrusion ratios and lengths in the forward and backwarddirections, the simultaneous completion of the material flowin the both directions is very difficult. Consequently, one ofthe directions is completed early, then material flow stoppedand dead metal zone appears in this part just like that in theconventional process.Therefore, in the case of piston-pin forming, the extrusionratio and the length of both directions are the same at 1.89and51mm.First,analysisofopendieforwardbackwardex-trusion is performed for an investigation of extrusion lengthsof the piston-pin. The difference of two extruded ribs is24.9mm and the backward extruded rib is shorter than theforward extruded rib as shown in Fig. 6.The metal flow of backward direction must be restrictedcompulsorily for the satisfaction of the design conditionsand this means the occurrence of a dead metal zone. There-fore, for the same extrusion length in both directions, threeFig. 6. Extrusion length in forwardbackward extrusion.D.J. Lee et al./Journal of Materials Processing Technology 139 (2003) 422427425Fig. 7. Modified process sequence for a multi-stage former.methods are proposed to control the metal flow without thecompulsory restriction of metal flow3.1. Change of preform shapeTo secure the same length of both directions from thecenter of web, it is required that the backward extrudedrib is performed by preform design as the difference ofboth-direction lengths at 24.9mm from the above results,before forwardbackward extrusion. Fig. 7 shows the mod-ified process sequence, and Fig. 8 shows the metal flow ofthe final stage of forwardbackward extrusion in this case.From the results of simulation, the lengths of two extrudedribs are 51mm, which is the dimension of the piston-pin andsatisfied the design condition. In addition, the metal flow isuniform in the defect zone where the flow defect occurredin the conventional process, and there is not a discontinu-ity of velocity in both extrusion directions. This means thatmetal flows uniformly in the whole process without a deadmetal zone by restriction of metal flow.Fig. 8. Metal flow of web in case of using preform.Fig. 9. Schematic diagram of the axially moving container die structure.3.2. Driving of extrusion containerThe driving extrusion container method 9 is used formetal flow control for the satisfying of the design condi-tion. This structure is that the extrusion container is movedin the counter direction to the early extruded one (Fig. 9).This has the effect of increasing the metal flow in the lateextruded direction and restricting metal flow in the early ex-truded direction. In the case of the piston-pin, because ofthe early completion of backward extrusion, the extrusioncontainer is moved in the forward direction for the increaseof metal flow to this direction. In this process, the princi-pal process variables are the relative velocity ratio of thepunch and the moving extrusion container, and the frictioncondition between the material and the moving extrusioncontainer.In this study, because the friction factor, m, is 0.1 be-tween the material and container, simulation is performedonly according to the variation of the relative velocity ratio(VC/VP= 0.1, 0.25, 0.5, 0.75, 1.0). If the relative velocityratio is smaller than the optimum which can complete form-ing simultaneously, extrusion in the backward direction iscompleted earlier than in the forward direction and a flowdefect occur in the same part as in the conventional process.Otherwise, if the relative velocity ratio is larger than the op-timum one, extrusion in the forward direction is completeearlier than backward direction and a flow defect occurs inthe opposite part to where a defect occurs in the conven-tional process.Therefore, for satisfaction of the design conditions, theoptimum relative velocity ratio is searched for by an opti-mization technique, the bisection method. From the result,the optimum relative velocity ratio is 0.48. Figs. 10 and 11show the deformation modality and metal flow according tothe relative velocity ratio (0.1, 0.48, 1.0) for a punch strokeof 42.7mm, respectively. Fig. 11(c) shows the metal flow426D.J. Lee et al./Journal of Materials Processing Technology 139 (2003) 422427Fig. 10. Deformation modality of the piston-pin according to the relative velocity ratio.Fig. 11. Comparisons of metal flow according to the relative velocity ratio.at the optimum relative velocity (0.48) where an improvedflow pattern without a flow defect can be noted.3.3. Modification of die structureA modification of the die structure is proposed whichcan restrict the metal flow of backward direction, which isdeformed early, for simultaneous completion of extrusion inboth directions. In this case, for simultaneous completionand the same length in both directions, the stripper, which isFig. 12. Schematic diagram of die structure using stripper.equipmentforpunchextractionfromproducts,isredesigned.If a fixed stripper of conventional type is used, a dead metalzone appears from the middle stage of backwardforwardextrusion by the restriction of material flow.Therefore, a structure is used that can delay the metal flowin the backward direction by spring force. Fig. 12 showsthe die structure. For this method, it is very important todecide the proper spring force for simultaneous completionof forming. Therefore, the necessary spring force for this iscalculated by FE simulation. From the simulation result, itwas 5t to be applied load to stripper. Fig. 13 shows metalflow in this case. The metal flow is similarly uniform at thedefect zone without discontinuity of velocity in comparisonwith other modification methods.Fig. 13. Metal flow of web in case of using stripper.D.J. Lee et al./Journal of Materials Processing Technology 139 (2003) 422427427Table 1Comparison process for each of the proposed methodConventional methodUse of preformUse of stripperUse of moving containerMaximum load (t)97.296.396.184.0Process of extrusion2 stage2 stage1 stage1 stageDefectExistNoneNoneNone4. Results and experimentFrom the FE simulation, the three proposed methodsare proper to prevent a flow defect by metal flow control.The characteristics of each process are as follows. The firstmethod that uses a preform needs three stage processes (pre-forming, forwardbackward extrusion, piercing) and has asimple die structure; however, the second method that usesa stripper and the third method that uses an axially mov-ing container need two-stage processes (forwardbackwardextrusion, piercing) and have a complex die structure. Inrespect of the forming load, the processes are similar toeach other.Especially,themaximumformingloadissmallerthanthatof other processes by about 10t in the case of the axiallymoving container, because the axially moving container in-creases material flow in the direction punch movement. It iscompared with the proposed method for forming by a pressin Table 1. In this study, an experiment using a preform isperformed and uses a multi-stage former having 250t ca-pacity for the verification of simulation. Etching for obser-vation of metal flow is performed to examine for a flowdefect for the piston-pin before piercing. Fig. 14 showsthe experiment result, based on the first proposed method,changing the preform. The experiment result shows thatmetal flow is uniform in the defect zone where the flow de-fect had occurred, and satisfied the simultaneous completionof forming and the same length in both extrusion directions.This tendency is in good agreement with the simulationresult.Fig. 14. The elimination of the flow defect by the first proposed method.5. ConclusionsIn this study, the flow defect that occurs in the manu-facturing process of the piston-pin is examined and a newprocess to prevent the defect is redesigned by FE analysis.First, the cause of the defect is investigated, and the analyti-cal approach is verified by comparison o
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