Title: A study on process design of plate cold forging for machinability improvement of piston under drive brake

Authors: Haksun Lee; Myoungpyo Hong; Donghwan Choi; Youngsuk Kim

Addresses: Research and Development Centre, OTO Industry Co., Ltd., 60 sinpyeonggongdan-gil, Gyeongju 780-905, Republic of Korea; School of Mechanical Engineering, Kyungpook National University, 80 Daehak-ro, Daegu 702-701, Republic of Korea ' Ultimate manufacturing Technology Centre, Korea Institute of Industrial Technology, 320 Techno sunhwan-ro, Daegu 711-883, Republic of Korea; School of Mechanical Engineering, Kyungpook National University, 80 Daehak-ro, Daegu 702-701, Republic of Korea ' Intelligent Manufacturing System, Korea Institute of Material Science, 797 Changwondaero, Changwon 642-831, Republic of Korea ' School of Mechanical Engineering, Kyungpook National University, 80 Daehak-ro, Daegu 702-701, Republic of Korea

Abstract: Reduction of energy in manufacturing industries is a current issue to keep the earth green. This energy saving yields the cost reduction in automotive industries. Many automotive part companies try to improve their manufacturing process to save the manufacturing energy. Specially, many attempts on changing the hot forging process into the cold forging process of plate forging have been tackled in the piston under drive brake used in an automotive transmission module. The turning process after hot forging changed to turning after plate cold forging for the energy and cost reduction. But two extrusion shapes in an outermost diameter of part let fall tool life by interrupted cut in turning. Therefore, it needs thickness reduction of two extrusion areas in the outermost diameter. This study suggests an effective way to reduce the thickness of interrupted cut in forging stage.

Keywords: plate forging; cold forging; interrupted cutting; automatic transmission; hot forging; machinability evaluation; process design; pistons; drive brakes; automotive components; automobile industry; energy consumption; energy saving; turning; cost reduction; extrusion shapes; tool life; thickness reduction.

DOI: 10.1504/IJMPT.2017.080570

International Journal of Materials and Product Technology, 2017 Vol.54 No.1/2/3, pp.88 - 107

Received: 18 Jul 2015
Accepted: 28 Nov 2015

Published online: 31 Oct 2016 *

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