A spring washer is a fastening machine element that lowers excessive contact pressures between screws and fasteners, such as automobile suspensions, and at the same time prevents loosening. Spring washers are generally manufactured by drawing, coiling, and heat-treating processes of wire rods of cir...
A spring washer is a fastening machine element that lowers excessive contact pressures between screws and fasteners, such as automobile suspensions, and at the same time prevents loosening. Spring washers are generally manufactured by drawing, coiling, and heat-treating processes of wire rods of circular cross-section, and improving the mechanical properties to meet the specifications. However, in this manufacturing process, there are many problems such as low production efficiency, high manufacturing cost, thermal deformation and residual stress due to heat treatment. In addition, due to the nature of automotive parts, spring washer is in high demand. This situation requires low manufacturing costs and high quality. In this respect, a roller drawing process using hard drawn steel wire excluding heat treatment is required. The roller-drawing is a metal forming process that reduces cross sectional area and increases length of wire. The drawing is classified as a hot rolling and cold rolling based on performance temperature. As the strength of the drawing material increases in the roller drawing process, the roller dies are easily abraded. Therefore, in this thesis preferable to apply cemented carbide material to the drawing roller of high strength wire. In the part where the part is formed in a trapezoidal shape, the part in contact with the material may cause wear and roller dies damage due to stress concentration, thereby manufactured a roller having a cemented alloys tool steel. Therefore, in this paper desirable to design suggestion for reduce the damage caused by interference. In this thesis, predictions of forming limits in roller drawing process has been simulated by using commercial FEM code deform-3D. The simulated results were compared with experimental ones and conclude as follows;
1. The roller-drawing is the new process applying hard drawn steel wire from the trapezoidal cross section in a typical drawing process.
2. The roller-drawing process using hard drawn steel wire could reduce spring washer manufacture process and save the amount of manufacturing cost.
3. Simulated results are in good agreement with experimental ones. For this study, the analysis result predicted by FEM will be useful for reducing the trial and error and optimizing in progress design of roller-drawing in hard drawn steel wire spring washer process.
4. As the tensile stress reach the yield strength of the material, fracture defect occur. Consequently, it will be possible to result of analysis of roller-drawing process by using the yield strength of the materials.
A spring washer is a fastening machine element that lowers excessive contact pressures between screws and fasteners, such as automobile suspensions, and at the same time prevents loosening. Spring washers are generally manufactured by drawing, coiling, and heat-treating processes of wire rods of circular cross-section, and improving the mechanical properties to meet the specifications. However, in this manufacturing process, there are many problems such as low production efficiency, high manufacturing cost, thermal deformation and residual stress due to heat treatment. In addition, due to the nature of automotive parts, spring washer is in high demand. This situation requires low manufacturing costs and high quality. In this respect, a roller drawing process using hard drawn steel wire excluding heat treatment is required. The roller-drawing is a metal forming process that reduces cross sectional area and increases length of wire. The drawing is classified as a hot rolling and cold rolling based on performance temperature. As the strength of the drawing material increases in the roller drawing process, the roller dies are easily abraded. Therefore, in this thesis preferable to apply cemented carbide material to the drawing roller of high strength wire. In the part where the part is formed in a trapezoidal shape, the part in contact with the material may cause wear and roller dies damage due to stress concentration, thereby manufactured a roller having a cemented alloys tool steel. Therefore, in this paper desirable to design suggestion for reduce the damage caused by interference. In this thesis, predictions of forming limits in roller drawing process has been simulated by using commercial FEM code deform-3D. The simulated results were compared with experimental ones and conclude as follows;
1. The roller-drawing is the new process applying hard drawn steel wire from the trapezoidal cross section in a typical drawing process.
2. The roller-drawing process using hard drawn steel wire could reduce spring washer manufacture process and save the amount of manufacturing cost.
3. Simulated results are in good agreement with experimental ones. For this study, the analysis result predicted by FEM will be useful for reducing the trial and error and optimizing in progress design of roller-drawing in hard drawn steel wire spring washer process.
4. As the tensile stress reach the yield strength of the material, fracture defect occur. Consequently, it will be possible to result of analysis of roller-drawing process by using the yield strength of the materials.
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