Date post: | 16-Apr-2017 |
Category: |
Engineering |
Upload: | interplex-holdings |
View: | 538 times |
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What is the Concept?
COLD FORGING Ironing / Upsetting Extrusion / Trimming
CONVENTIONAL STAMPING Blanking / Drawing / Forming Piercing / Bending
PRECISION COLD FORGED STAMPINGBlanking/ Drawing/ Forming / Piercing / Bending
Ironing / Upsetting /Extrusion / Trimming
3D PARTS
Machine Part to Cold Forge Part
Precision Cold Forged Progressive Stamping
3-D forming capability
Precision Forming of 1) Flatness/Parallelism2) Sharp edges3) Corners4) Material Thickness: 2.0 – 3.6 mm
Precision Cold Forged Progressive Stamping
Forging – Material “Thickening” to 2x raw material thickness
Cross Sectional View
Precision Cold Forged Progressive Stamping
Merits:
High quality 3D parts produced
High efficiency
High accuracy & repeatability in parts replacements
Longer tool life
3-D precision cold-forging
OPU
VCM for HDD
Precision Cold Forged Progressive Stamping
Earphone part
Die casting Cold Forging Stamping
Material: SPCC
Operation: (Progressive Die)
a. Cutting b. Upsetting c. Trimming d. Cut off
Process innovation:
Utilizing cold forging instead of die-casting, we realized:
a. Improved Production efficiency
b. Improved strength
Upsetting
Precision Cold Forged Progressive Stamping
Application : Power Tool
Material : S65C
Old Process : Sintering & Machining
New Process : Cold Forged Stamping
Precision Cold Forged Progressive Stamping
Gear Detail
Electric Tool
Sintering Cold Forging Stamping
Material: S65C
Operation: (Progressive Die)
a. Cutting b. Upsetting c. Trimming d. Drawing
Process innovation:
Utilizing cold forging instead of sintering, we realized:
a. Improved Part Strength
b. Reduction in cost of > 60%
Precision Cold Forged Progressive Stamping
Application : Motor
Material : SPCC
Old Process : Sintering
New Process : Cold Forged Stamping
Merit : Improve production efficiency
: Improved strength Section Detail
Precision Cold Forged Progressive Stamping
Disc Clamp for HDD
Fine Blanking Cold Forging Stamping
Material: A1050
Operation: (Progressive Die)
a. Cutting b. Upsetting c. Forming
d. Trimming e. Cut off
Process innovation:
Utilizing cold forging instead of fine blanking, we realized:
a. Improved Part Strength
b. Shorter lead time for Mass Production
Precision Cold Forged Progressive Stamping
Application : HDD Disc Clamp
Material : A6061(铝镁合金)
Old Process : Assembly by two parts
New Process : Cold Forged Stamping plus minimum machining
Main Merit : Improve production efficiency & Reduce the cost
Precision Cold Forged Progressive Stamping
Stamping
Cold Forging Production
Machining / Thread Roll
Heat-treatment
Plating
Final Assembly
Simulation / DFM
Full
Prod
uctio
n / Q
A/ S
ale
& M
arke
ting
/ R&D
Set
up
Typical manufacturing processes for Cold Forged components
Vertical & Horizontal Cold Forging
Horizontal Forging
Vertical Forging
Vertical & Horizontal Cold Forging
1. High Mass Production Speed (SPM 80-400)
2. Net / Near net shape to eliminate or reduce secondary operations
3. Consistency / dimensional accuracy
4. Quality / surface finish
5. Low Material wastage & Elimination of scrap
6. Improvement in mechanical properties, greater strength to weight ratio, unbroken grain flow.
Benefits of Cold Forging
Vertical & Horizontal Cold Forging
Cold Forging Process Simulation
SIMULATION RESULT(DFM / PROGRESSION)
UG NX2 Delta-Mesh
DEFORM 3DTM
FORGE 2D TM
PAM-STAMP™
MATERIAL
STAMPING & COLD
FORGING
FRICTION
PRESS
Progression Example--- Engine ComponentsCombination use of Horizontal Forming + Vertical Forming
Vertical & Horizontal Cold Forging
Progression Example for Cold Forging Process
Vertical & Horizontal Cold Forging
Step 3 Step 4 Step 8 Step 9(Machining to complete
the part – 5% on Diameter)
An
nea
l &
Bon
der
izin
g
An
nea
l &
Bon
der
izin
g
An
nea
l &
Bon
der
izin
gStep 6Step 1
(Hollow Blank)
Anneal &Bonderizing
Step 31st Pre-Forge
Step 4Cut Out Outside
FlangeAnneal &
Bonderizing
Step 6Forge Internal
GearAnneal &
Bonderizing
Step 8Forge External GearEnd of Cold Forge
Step 1 Blanking
Step 9Machining
One piece Pinion Gear design forSafety Seat Belt.
Old Process – Full MachiningNew Process – Forging + Min. Machining
Vertical & Horizontal Cold Forging
Simulation
Process
Forming Tools
Laser WeldingStamping Blank
2 Pieces Pinion Gear design for Safety Seat Belt
Combination of Stamping + Forming + Piercing + Laser Weld
Cold forged components for Automotive application
Sample Products for Cold Forging
Thank You
http://www.interplex.com/cold-forging