Skip to main content
SpringerLink
Log in

A proposed Common Single-Die Exchange Technique (C-SDET) to enhance production of pulleys

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The success in developing a metal forming process is relied heavily on the design of a preform to reduce the final forming load at the final step. The design of the preform is considered a big burden of a process designer. Currently, the automotive companies try to design components which can cover a wide range of car models, but only changing a few dimensions to accommodate different models. However, each product is still considered a single product during the process design. Therefore, if only one preform can cover a variety of products, the process design could speed-up and gain more benefits in the production. In this research, a technique to design preform for various product models was proposed. The aim of this technique is to develop generalized common preforms by utilizing the same part configuration/shape but different dimensions in some areas to reduce the number of preform and process design time. This technique is composed of two steps: (a) classification of product groups and (b) determination of the common tool for producing the common parts. This technique was applied to the cold forging process to produce various models of automotive pulleys. The results show that the number of preforms was reduced by almost 70%, and the die changeover time was approximately saved by 75 min per shift (8 h/shift), and the capacity was gained by 1800 pieces per shift without generating any product defects.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32

Similar content being viewed by others

References

  1. Park JJ, Rebelo N, Kobayashi S (1983) A new approach to preform design in metal forming with the finite element method. Int J Mach Tool Des Res 23(1):71–79. https://doi.org/10.1016/0020-7357(83)90008-2

    Article  Google Scholar 

  2. Kim N, Kobayashi S (1990) Preform design in H-shaped cross sectional axisymmetric forging by the finite element method. Int J Mach Tools Manuf 30(2):243–268. https://doi.org/10.1016/0890-6955(90)90134-5

    Article  Google Scholar 

  3. Kang BS, Kim N, Kobayashi S (1990) Computer-aided preform design in forging of an airfoil section blade. Int J Mach Tools Manuf 30(1):43–52. https://doi.org/10.1016/0890-6955(90)90040-P

    Article  Google Scholar 

  4. Thiyagarajan N, Grandhi RV (2005) Multi-level design process for 3-D preform shape optimization in metal forming. J Mater Process Technol 170(1–2):421–429. https://doi.org/10.1016/j.jmatprotec.2005.05.051

    Article  Google Scholar 

  5. Di Lorenzo R, Micari F (1998) An inverse approach for the design of the optimal preform shape in cold forging. CIRP Ann 47(1):189–192. https://doi.org/10.1016/S0007-8506(07)62815-7

    Article  Google Scholar 

  6. Sheu JJ, Yu CH (2009) Preform and forging process designs based on geometrical features using 2D and 3D FEM simulations. Int J Adv Manuf Technol 44(3–4):244–254. https://doi.org/10.1007/s00170-008-1834-5

    Article  Google Scholar 

  7. Yang C, Ngaile G (2010) Preform design for forging and extrusion processes based on geometrical resemblance. Proc Inst Mech Eng B J Eng Manuf 224(9):1409–1423. https://doi.org/10.1243/09544054JEM1799

    Article  Google Scholar 

  8. Altan T, Ngaile G, Shen G (2004) Cold and hot forging: fundamentals and applications, vol 1. ASM international, pp 67–81

Download references

Author information

Authors and Affiliations

  1. Materials and Production Engineering program, Mechanical and Process Engineering Department, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB), Bangkok, Thailand

    Nara Nakeenopakun & Yingyot Aue-u-lan

  2. Material Manufacturing and Surface Engineering Research Center, 1518 Pracharat Sai 1 Road, Wongsawang, Bangsue, Bangkok, Thailand

    Yingyot Aue-u-lan

Authors
  1. Nara Nakeenopakun
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yingyot Aue-u-lan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yingyot Aue-u-lan.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nakeenopakun, N., Aue-u-lan, Y. A proposed Common Single-Die Exchange Technique (C-SDET) to enhance production of pulleys. Int J Adv Manuf Technol 107, 3625–3643 (2020). https://doi.org/10.1007/s00170-020-05267-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05267-0

Keywords

Search

Navigation