슬래브법을 이용한 회전 다이 플랜지 업세팅 공정 해석

This study intends to reduce forming load by adding die rotation to flange-upsetting process. Materials are formed by the compression and rotational torque which are accrued from rotation of the lower die accompanied by axial compression of the punch. For the theoretic analysis of flange-upsetting process using rotation die, slab method was used. Furthermore, for the verification of the theoretic analysis results, FEM simulation using DEFORM 3D a commercial software was done, and through the model material experiment using Prasticine, the results were compared and reviewed. Flange-upsetting process using rotation die shows reduced forming load compared with process without die rotation and demonstrates uniform distribution of strain. And as for the effect of the reduction of forming load, the less the aspect ratio(h0/d0) and the greater friction coefficient, the greater effect is. With increase in die rotation velocity, the effect of forming load reduction also increases little by little, but its effect on forming load reduction is very negligible compared with other forming parameters. Theoretic analysis results and simulation results coincided pretty well. The flange-upsetting process using die rotation are evaluated as useful process that can produce reduction of forming load and uniform strain.