© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Spring forming machine• Spring forming machine controlled by mechanical cam and link.

http://ma.gnu.ac.kr/vod/Forming/Spring_Former.wmv Spring former

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Rotary Swaging

• Split dies separate and close to reduce the diameter and produce a taper of tube.

Tube

Die

Mandrel

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Tube (Pipe) Bending• Straight tube is bended into the desired form.• Be careful to buckle inward during bending.

http://ma.gnu.ac.kr/vod/forming/Pipe_Bending.wmv

Form

er

Clamp

Tube bending

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Tube Hydroforming

SME: http://www.youtube.com/watch?v=nylIvins3XECom: http://www.youtube.com/watch?v=i2ac6A3FJ6E&hl=ko

• Hydraulic pump injects high pressure fluid inside a hollow tube to expand until it matches a negative mold.

• Strong and light structures for vehicles

Dies

Seals

Hydraulicpressure Tube

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Characteristics ( 특징 )

Advantages Disadvantages

Fast & mass production Expensive equipment and dies

Improved strength Ductile materials

Surface finish and tolerance are better than casting

Shape is limited by strain/flowSize is limited by force/equipment

Strength is improved because of work hardening, grain refining, fevering, defect closureSurface finish and tolerance are better than casting, worse than machining

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Economics ( 경제성 )• Tool and die cost middle or high but spread over the

number of parts• For large quantities forging is more economical than sand

casting

100 101 102 103 104 105 106

Number of pieces

Cos

t per

pie

ces

1 2

3

4

5

6 7

8

9

Sandcasting

Investment casting

Die casting

Forging

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

Bulk Deforming Simulation• http://www.afdex.com

© 2012 Su-Jin Kim GNU© 2012 Su-Jin Kim GNU

Bulk DeformingBulk DeformingManufacturing ProcessesManufacturing Processes

References• http://www.afdex.com• http://deform.co.kr• http://www.posco.co.kr