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