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Abstract 8

Nomenclature 17

第1章 서론 18

1.1. 연구 배경 19

1.2. 국내외 기술동향 26

1.2.1. 국내의 기술 현황 26

1.2.2. 국외의 기술 현황 28

참고 문헌 30

第2章 리클라이너의 구조 해석 32

2.1. 서언 33

2.2. 재료 시험 및 구조 해석 방법 34

2.2.1. 재료 시험 34

2.2.2. 구조 해석 36

2.3. 결과 및 고찰 40

2.3.1. 재료 시험 40

2.3.2. 구조 시험 47

2.4. 결언 51

참고 문헌 52

第3章 CAE를 이용한 파인 블랭킹 성형 해석 54

3.1. 서언 55

3.2. 해석 방법 57

3.2.1. 섹터 기어 파인 블랭킹 금형의 응력 해석 57

3.2.2. 성형해석을 통한 공정 및 제품 설계 변수 60

3.3. 결과 및 고찰 62

3.3.1. 천공 공정 해석 62

3.3.2. 클리어런스에 따른 펀치 하중 및 응력 평가 64

3.3.3. 소재 두께의 변화에 대한 펀치 하중 및 응력 평가 68

3.3.4. 예비 천공(Pre-piercing)과 천공(Hole piercing)의 펀치 하중 비교 71

3.3.5. 클리어런스와 소재 두께의 변화에 따른 다이 롤 크기 평가 74

3.4. 결언 78

참고 문헌 80

第4章 파인 블랭킹을 위한 금형 최적화 82

4.1. 서언 83

4.2. 인장 시험 및 수치 해석 86

4.2.1. 연성파괴 조건 86

4.2.2. 임계값의 결정 87

4.2.3. 유한요소 모델링 91

4.2.4. 유한요소 경계조건 91

4.2.5. 물성 데이터 94

4.3. 결과 및 고찰 96

4.3.1. 공정변수의 영향 분석 96

4.3.2. 클리어런스 영향 101

4.3.3. 광택면과의 V-돌기 높이의 관계 103

4.3.4. 광택면과의 V-돌기 위치의 관계 105

4.3.5. 광택면과의 블랭크 홀더력의 관계 107

4.3.6. 광택면과의 카운터 펀치력의 관계 109

4.4. 결언 111

참고 문헌 112

第5章 파인 블랭킹을 적용한 리클라이너 신뢰성 평가 115

5.1. 서언 116

5.2. 열 변형 해석 및 신뢰성 시험 117

5.2.1. 소재의 열처리 117

5.2.2. 록 기어의 유한요소 모델링 119

5.2.3. 공정 변수에 따른 열처리 121

5.2.4. 시작품의 신뢰성 시험 122

5.3. 결과 및 고찰 127

5.3.1. 열처리 공정변수에 따른 경도 특성 127

5.3.2. 성형/열처리 후 부품 형상 및 치수 평가 135

5.3.3. 열처리 후 표면 경도 138

5.3.4. 시제품의 신뢰성 평가 141

5.4. 결언 147

참고 문헌 149

第6章 결론 151

발표논문 목록 156

표목차

Table 1.1. Comparison between general blanking and fine blanking 21

Table 1.2. Comparison of characteristics between conventional fine blanking... 23

Table 2.1. Number of nodes and elements for each part 39

Table 2.2. Mechanical properties of SNCM220 46

Table 3.1. Analysis conditions of piercing process for sector gear with 59

Table 3.2. Analysis conditions of piercing process for sector gear 59

Table 4.1. Mechanical properties of SNCM220 95

Table 4.2. Fixed geometric parameters for FEA 97

Table 4.3. Variable process parameters for FEA 98

Table 5.1. Mechanical properties of SNCM220 118

Table 5.2. Eight types of process parameters 122

Table 5.3. ANOVA table for the hardness in the middle of a... 132

Table 5.4. ANOVA table for the hardness at the root of a tooth 132

Table 5.5. Results of static test of each part 143

Table 5.6. Result of durability test 146

그림목차

Fig. 1.1. Multi step recliner. (a) Austem. co. kr and (b) sector gear parts of 3... 23

Fig. 1.2. Seat recliners of domestic 27

Fig. 1.3. Seat recliners of foreign 28

Fig. 1.4. The structure of car seat recliner 29

Fig. 2.1. Dimensions and shape of the specimen for tensile test (KS B... 35

Fig. 2.2. The condition of heat treatment 36

Fig. 2.3. Finite element model of a standard round recliner 38

Fig. 2.4. Boundary condition for finite element analysis 39

Fig. 2.5. Stress-strain curve of SNCM220 sheet (4.0t) domestic 41

Fig. 2.6. Stress-strain curve of SNCM220 sheet (4.5t) domestic 42

Fig. 2.7. Stress-strain curve of SNCM220 sheet (5.0t) domestic 43

Fig. 2.8. Stress-strain curve of SNCM220 sheet (5.0t) imported 44

Fig. 2.9. Stress-strain curve of SNCM220 sheet (6.0t) imported 45

Fig. 2.10. Distribution of effective stress 48

Fig. 2.11. Distribution of effective strain 49

Fig. 2.12. Relationship between reaction moment and rotational... 50

Fig. 3.1. Model definition of piercing process analysis for sector gear 58

Fig. 3.2. Die roll measurement after piercing process 61

Fig. 3.3. Analysis result with 0.5 % clearance 63

Fig. 3.4. Stress distribution with 0.5 % clearance 65

Fig. 3.5. Hysteresis diagram of forming load according to clearance... 66

Fig. 3.6. Maximum stress of punch according to clearance change 67

Fig. 3.7. Hysteresis diagram of punch load according to workpiece... 69

Fig. 3.8. Maximum equivalent stress of punch according to workpiece... 70

Fig. 3.9. Analysis model for pre-piercing process 72

Fig. 3.10. Analysis result of pre-piercing process 72

Fig. 3.11. Analysis result of pre-piercing and hole piercing process 73

Fig. 3.12. Punch load comparison of pre-piercing and hole piercing... 74

Fig. 3.13. Relation between clearance die roll 76

Fig. 3.14. Relation between workpiece thickness and die roll 77

Fig. 4.1. Specimen for tensile test 88

Fig. 4.2. Photo of tensile specimen 88

Fig. 4.3. 3D FEM model for tensile test 88

Fig. 4.4. Fractured specimen after tensile test 90

Fig. 4.5. Comparison of fractured surface through FEM 90

Fig. 4.6. Finite element model for fine blanking simulation 92

Fig. 4.7. Boundary condition for fine blanking simulation 93

Fig. 4.8. Stress-strain curve of SNCM220 sheet 94

Fig. 4.9. Definition of geometric and process parameters 97

Fig. 4.10. Distribution of in holding and shearing process effective strain 99

Fig. 4.11. Distribution of damage factor 100

Fig. 4.12. Influence of clearance on burnish zone 101

Fig. 4.13. Comparison of sheared surfaces with different clearances 102

Fig. 4.14. Influence of V-ring height on burnish zone 103

Fig. 4.15. Comparison of sheared surfaces with different V-ring heights 104

Fig. 4.16. Influence of V-ring position on burnish zone 105

Fig. 4.17. Comparison of sheared surfaces with different V-ring positions 106

Fig. 4.18. Influence of holding force on burnish zone 107

Fig. 4.19. Comparison of sheared surfaces with different holding forces 108

Fig. 4.20. Influence of counter punch force on... 109

Fig. 4.21. Comparison of sheared surfaces with different counter punch... 110

Fig. 5.1. Quenching process 118

Fig. 5.2. Tempering process 118

Fig. 5.3. Geometry of a lock gear 120

Fig. 5.4. Finite element model of lock gear 120

Fig. 5.5. Diagram of static test for recliner 124

Fig. 5.6. Diagram of drop test for recliner 125

Fig. 5.7. Diagram of impact test for recliner 125

Fig. 5.8. Impact test of right and left at recliner 126

Fig. 5.9. Diagram of durability test for recliner assembly 126

Fig. 5.10. Distribution of carbon content in thickness direction 128

Fig. 5.11. Hardness distribution 129

Fig. 5.12. Hardness distribution in thickness direction 131

Fig. 5.13. Distribution of hardness in the optimum process condition 133

Fig. 5.14. Volume change in heat treatment process 134

Fig. 5.15. Dimensional change of a tooth before and after heat... 136

Fig. 5.16. Dimensional change after quenching 137

Fig. 5.17. Creation of carburized layer after quenching 138

Fig. 5.18. Distribution of hardness 139

Fig. 5.19. Distribution of hardness in three case conditions 140

Fig. 5.20. Result of static test of guide embossment part 141

Fig. 5.21. Result of static test of embossment part 142

Fig. 5.22. Result of static test of sector gear part 142

Fig. 5.23. Results of drop test at height of 500 ㎜ 144

Fig. 5.24. Results of impact test 145

Fig. 5.25. Decomposed recliner after impact test 145

초록보기

 Fine-Blanking technique was increasingly used worldwide in 1980's to produce high quality products with lower consumption of energy. Korean industry followed same trend and increasing number of small and medium size industries as well as large one used Fine-Blanking technique. As a result of this past industrial practice, the Know-How of die design and process control for Fine-Blanking has been accumulated to some extent in Korean industry. In developed countries, researches have been done on surface coating of dies, development of appropriate die materials and associated surface treatment method. Also, significant efforts are being made to enhance the application of Fine-Blanking technique in conventional forming processes such as cold forging. For this purpose, relatively expensive Fine-Blanking equipments have to be incorporated into the conventional forming equipments. In this regard, large efforts are being made for the cost effective implementation and operation of multiphase forming processes integrated with Fine-Blanking phase.

Since most of multiphase Fine-Blanking dies are progressive ones. The control of accuracy is most important. Therefore, Jig Grinding M/C is essential and the feed should be less than 10㎛. Because of above reasons, Fine-Blanking die becomes so expensive. It is suggested that the whole process is divided and Fine-Blanking technology is adopted when it is required.

The Fine-Blanking technology experiment of thin plate has shown that the minimum burr exists in cut surface and if this surface has some function, this burr should be eliminated.

The multiphase Fine-Blanking die design technology and expertise used in this project will be available to many small size industries which plan to produce high precision parts by Fine-Blanking process based in conventional press.

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