Most of automobile steering parts are manufactured through the multi-stage cold forging process using round-bar drawn materials. The same process is applied to the ball stud parts of the outer ball joint, and various research activities are being carried out to reduce the extreme manufacturing cost in order to survive in the limitless competition. In this paper, we present a quantitative prediction method for the limiting life of the die as a method for cost reduction in the multi-stage cold forging process. The load on the die was minimized by distributing the forming load based on process optimization through finite element analysis. In addition, based on the quantitative prediction algorithm of the limiting life of the die, the application of the split die and the optimization of the phosphate treatment of the material surface are presented as a conclusion as a method to improve the limiting life of the die.

Molding is the root industry of the manufacturing as a means to mass-produce developed prototypes. Molds are typically divided into injection molds and press mold industries. Injection molds produce the products by injection of molten plastic into a mold, and press molds are molded and bended plate. The ejection system, such as eject pins, is used to separate the manufactured products from the mold, which involves a number of hole operations. Location, diameter and depth of holes are often tabulated and managed collectively when designing 2D drawings. The design efficiency was realized by applying CATIA Automation to the 3D model and bringing in the data of the holes in the Excel data.

The driving efficiency in vehicles depends on a weight lightening of wheels. Lightweight aluminum wheel research has been widespread over the years. Carbon wheels reduce weight by 50% compared to aluminum wheels and have high tensile strength and low heat absorption. This study was investigated to apply the carbon fiber of molding pressure to produce the carbon wheel. Carbon wheel of mold structure analysis was performed.

The objective of this study is to investigate the effect of closed and open type on the load characteristics and amount of waste in tubular shaft and solid shaft for optimal design. The open and closed type were designed by 6 stage processes and applied for analysis. The coefficient of friction was set to Oil_Cold conditions as refer to the analysis library. It is found that the actual underfill phenomenon was not observed on the closed and open type. The metal flow of the closed and open type are revealed that the folding phenomenon was not occurred, thus there is no problem in actual production. The load characteristics are similar from stage 1 to stage 3 due to the same geometry of upper and lower die. However, tubular shaft and solid shaft are decreased 26% and 32% load from stage 4 to stage 6. In case of open type, amount of waste of tubular shaft and solid shaft are 11g and 14g, respectively.

In this study, the effect of upper die type on the load characteristics of lower die and the wasted material was studied numerically. The open and closed types of upper die were applied for each stage and the results are analyzed using a finite element analysis method. The half of x,y plane was analyzed due to the symmetrical shape in order to reduce the analysis time. The coefficient of friction was set to Soap_Cold conditions as refer to the analysis library. It was revealed that a lot of underfill portion was observed the open type in stage 4. As a result of the maximum and minimum values of the max principal stress, closed type case much receives compressive stress about 620MPa-2019MPa. In case of open type, The load was reduced in all direction at each stage

On-machine automatic measuring software from 3-D solid modeler is generally applied to assess the functional performance of a final produce for computer numerical control (CNC) machine. Automatic measuring software may also be performed on individual components of CNC machine in which some functional aspect of the component must be examined and cannot be implicity determined by means of a mechanical inspection. The manufacturing specialist, combined with the appropriate software simulation, can not only create the commands to drive the virtual measuring but also can check for mistakes by viewing the computer graphics simulation of the tool cutting sequence.