1. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Spring forming machine Spring forming machine controlled by mechanical cam and link. http://ma.gnu.ac.kr/vod/Forming/Spring_Former.wmvhttp://ma.gnu.ac.kr/vod/Forming/Spring_Former.wmv Spring former

2. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Rotary Swaging Split dies separate and close to reduce the diameter and produce a taper of tube. Tube Die Mandrel

3. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Tube (Pipe) Bending Straight tube is bended into the desired form. Be careful to buckle inward during bending. http://ma.gnu.ac.kr/vod/forming/Pipe_Bending.wmv Former Clamp Tube bending

4. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Tube Hydroforming SME: http://www.youtube.com/watch?v=nylIvins3XE http://www.youtube.com/watch?v=nylIvins3XE Com: http://www.youtube.com/watch?v=i2ac6A3FJ6E&hl=kohttp://www.youtube.com/watch?v=i2ac6A3FJ6E&hl=ko Hydraulic pump injects high pressure fluid inside a hollow tube to expand until it matches a negative mold. Strong and light structures for vehicles Dies Seals Hydraulic pressure Tube

5. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Characteristics ( 특징 ) AdvantagesDisadvantages Fast & mass productionExpensive equipment and dies Improved strengthDuctile materials Surface finish and tolerance are better than casting Shape is limited by strain/flow Size is limited by force/equipment Strength is improved because of work hardening, grain refining, fevering, defect closure Surface finish and tolerance are better than casting, worse than machining

6. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Economics ( 경제성 ) Tool and die cost middle or high but spread over the number of parts For large quantities forging is more economical than sand casting 10 0 10 1 10 2 10 3 10 4 10 5 10 6 Number of pieces Cost per pieces 1 2 3 4 5 6 7 8 9 Sand casting Investment casting Die casting Forging

7. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes Bulk Deforming Simulation http://www.afdex.com

8. © 2012 Su-Jin Kim GNU Bulk Deforming Manufacturing Processes References http://www.afdex.com http://deform.co.kr http://www.posco.co.kr