Skip to main content
SpringerLink
Log in

Process design of multi-stage cold forging with small size for ESC solenoid valve parts

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

ESC’s solenoid valves independently brake each wheel, allowing the vehicle to maintain braking and directional stability. The most important component of the solenoid valve is the armature manufactured by the turning process by a CNC lathe so far. In this study, we propose to use the multi-stage cold forging process as an alternative to reduce manufacturing cost while satisfying dimensional accuracy and performance. To apply the multi-stage cold forging process, the whole forming process is divided into six stages to improve the dimensional accuracy of the outer diameter, full length and slot part of the armature. It is divided into 6 stages, but 6 stages are operated simultaneously in one stroke of forging. Inducing uniform plastic deformation by designing the preform for each stage of the armature slot. Through the proposed process design for the multi-stage cold forging process, the dimensional accuracy of the test product can be improved. The weight of the input material in the turning process can be reduced by 46 % from 3.5 g to 1.9 g by applying the multi-stage cold forging process. In addition, the manufacturing process can be reduced from 2 processes to 1 process, and the production quantity can be increased by 2500 % from 180 ea to 4800 ea per hour.

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

Similar content being viewed by others

Abbreviations

B :

Magnetic flux density, T

References

  1. K. Lange, Some aspects of the development of cold forging to a high-tech precision technology, Journal of Materials Processing Technology, 35(3–4) (1992), 245–257.

    Article  Google Scholar 

  2. J. Knust, F. Podszus, M. Stonis, B. A. Behrens, L. Overmeyer and G. Ullmann, Preform optimization for hot forging processes using genetic algorithms, The International Journal of Advanced Manufacturing Technology, 89 (2017), 1623–1634.

    Article  Google Scholar 

  3. T. W. Ku, A combined cold extrusion for a drive shaft: a parametric study on tool geometry, Materials, 13(10) (2020), 2244.

    Article  Google Scholar 

  4. Y. L. Chang, F. Y. Hung and T. S. Lui, A new infrared heat treatment on hot forging 7075 aluminum alloy: microstructure and mechanical properties, Materials, 13(5) (2020), 1177.

    Article  Google Scholar 

  5. S. Y. Hsia and P. Y. Shih, Wear improvement of tools in the cold forging process for long hex flange nuts, Materials, 8(10) (2015), 6640–6657.

    Article  Google Scholar 

  6. S. Fujikawa, H. Yoshioka and S. Shimamura, Cold and warm forging applications in the automotive industry, Journal of Materials Processing Technology, 35(3–4) (1992), 317–342.

    Article  Google Scholar 

  7. T. W. Ku and B. S. Kang, Tool design and experimental verification for multi-stage cold forging process of the outer race, International Journal of Precision Engineering and Manufacturing, 15 (2014), 1995–2004.

    Article  Google Scholar 

  8. T. W. Ku, L. H. Kim and B. S. Kang, Multi-stage cold forging and experimental investigation for the outer race of constant velocity joints, Materials and Design, 49 (2013), 368–385.

    Article  Google Scholar 

  9. Y. J. Choi, S. K. Lee, I. K. Lee, Y. J. Cho, J. W. Lee, J. W. Cho and M. S. Jeong, Multi-stage forging process design of steering system output shaft for reduction of energy consumption, International Journal of Precision Engineering and Manufacturing, 16 (2015), 1455–1460.

    Article  Google Scholar 

  10. M. S. Jeong, S. K. Lee, J. W. Yun, J. H. Sung, D. H. Kim, S. O. Lee and T. H. Choi, Green manufacturing process for helical pinion gear using cold extrusion process, International Journal of Precision Engineering and Manufacturing, 14 (2013), 1007–1011.

    Article  Google Scholar 

  11. J. H. Yun, M. S. Jeong, S. K. Lee, J. Y. Park and G. M. Kim, Sustainable production of helical pinion gears: environmental effects and product quality, International Journal of Precision Engineering and Manufacturing-Green Technology, 1 (2014), 37–41.

    Article  Google Scholar 

  12. A. R. Jo, M. S. Jeong, S. K. Lee, Y. H. Moon and S. K. Hwang, Multi-stage cold forging process for manufacturing a high-strength one-body input shaft, Materials, 14(3) (2021), 532.

    Article  Google Scholar 

  13. M. C. Sun, G. Y. Tzou and L. A. Zheng, Processing animation simulation and FEM analysis of multi-stage cold forging of stainless automotive battery fastener, Indian Journal of Engineering and Materials Sciences, 20(3) (2013), 219–224.

    Google Scholar 

  14. M. C. Sun, G. Y. Tzou and L. A. Zheng, Study on multi-stage cold forging of stainless automotive battery fastener, Applied Mechanics and Materials, 284–287(1) (2013), 211–215.

    Google Scholar 

  15. X. Zuo, Y. Wei, J. Chen, L. Zeng and X. Ruan, 3D FEM simulation of multi-stage forging process using solid modeling of forging tools, Journal of Materials Processing Technology, 91(1–3) (1999), 191–195.

    Article  Google Scholar 

  16. J. B. Kanani and D. I. Lalwani, An experimental and FEA investigation of near-net-shape cold forging of spur gear, Materialtoday: Proceedings, 44(1) (2021), 92–98.

    Google Scholar 

  17. T. Adean, The net-shape forming of gears, Materials and Design, 21(4) (2000), 271–278.

    Article  Google Scholar 

  18. V. Maegaard, Cold forging of net or near-net shape components, Journal of Materials Processing Technology, 35(3–4) (1992), 429–438.

    Article  Google Scholar 

  19. J. H. Yoon, H. W. Jeon and J. W. Lee, Process design of cold forging with thick plate for seat recliner parts, Materials and Design, 49 (2013), 449–455.

    Article  Google Scholar 

  20. H. S. Lee, M. P. Hong, D. H. Choi and Y. Kim, A study on process design of plate cold forging for machinability improvement of piston under drive brake, International Journal of Materials and Product Technology, 54(1–3) (2017), 88–107.

    Article  Google Scholar 

  21. B. Yılmaza, Ş. Karabulut and A. Güllü, A review of the chip breaking methods for continuous chips in turning, Journal of Manufacturing Processes, 49 (2020), 50–69.

    Article  Google Scholar 

  22. L. Johannesson, M. Asbogard and B. Egardt, Assessing the potential of predictive control for hybrid vehicle powertrains using stochastic dynamic programming, IEEE Transactions on Intelligent Transportation Systems, 8(1) (2007), 71–83.

    Article  Google Scholar 

  23. P. E. Wellstead and N. B. O. L. Pettit, Analysis and redesign of an antilock brake system controller, IEE Proceedings-Control Theory and Applications, 144(5) (1997), 413–426.

    Article  Google Scholar 

  24. L. Palkovics, Á. Semsey and E. Gerum, Roll-over prevention system for commercial vehicles-additional sensorless function of the electronic brake system, Vehicle System Dynamics, 32(4–5) (1999), 285–297.

    Article  Google Scholar 

  25. D. Margolis and T. Shim, A bond graph model incorporating sensors, actuators, and vehicle dynamics for developing controllers for vehicle safety, Journal of the Franklin Institute, 338(1) (2001), 21–34.

    Article  Google Scholar 

  26. M. M. Trivedi, T. Gandhi and J. McCall, Looking-in and looking-out of a vehicle: computer-vision-based enhanced vehicle safety, IEEE Transactions on Intelligent Transportation Systems, 8(1) (2007), 108–120.

    Article  Google Scholar 

  27. T. K. Bera, K. Bhattacharya and A. K. Samantaray, Evaluation of antilock braking system with an integrated model of full vehicle system dynamics, Simulation Modelling Practice and Theory, 19(10) (2011), 2131–2150.

    Article  Google Scholar 

  28. W. Chung, H. Song, D. Jung and T. Park, Development of a systematic process for hydraulic brake system design and for hot judder characteristic estimation, Journal of Mechanical Science and Technology, 26 (2012), 3893–3901.

    Article  Google Scholar 

Download references

Acknowledgments

This study was conducted under a purchase-linked project for small and medium-sized commercialization technology development and purchase conditional new technology development of the Ministry of SMEs and Startups. We thank the Ministry of SMEs and Startups for its support (S2860926) and the Korea Institute of Industrial Technology as “Development of intelligent root technology with add-on modules (KITECH Eo-200017). The performance test of the ESC assembly was conducted at EREA AMS Co., Ltd., Dalseong-gun, Daegu, Korea 42981.

Author information

Authors and Affiliations

  1. R&D Center, SUNGJIN FO-MA Inc., 93 Dalseodaero 109 gil, Dalseo-gu, Daegu, Korea

    Hak-Sun Lee & Sang-Gyun Park

  2. Graduate School, Kyungpook National University, 80 Daehak-ro, Daegu, Korea

    Hak-Sun Lee

  3. Mechanical Components and Materials R&D Group, Korea Institute of Industrial Technology, 320 Techno sunhwan-ro, Yuga-myeon, Dalseong-gun, Daegu, Korea

    Myoung-Pyo Hong

  4. School of Mechanical Engineering, Kyungpook National University, 80 Daehak-ro, Daegu, Korea

    Young-Suk Kim

Authors
  1. Hak-Sun Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sang-Gyun Park
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Myoung-Pyo Hong
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Young-Suk Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Young-Suk Kim.

Additional information

Hak-Sun Lee is Ph.D. student at Kyung-pook National University, Korea. He received his M.S. degree in Behavior of Fretting Fatigue at the Youngnam University. His research interests include forging analysis, machining characteristic and solenoid valve design in R&D Center of Sungjin Fo-Ma.

Young-Suk Kim received his M.S. degrees from the Department of Mechanical Engineering at Seoul National University in 1981. He obtained his Ph.D. degree from the Department of Mechanical Engineering at Kobe University in 1986. He is currently a Professor in the Department of Mechanical Engineering at Kyungpook National University. His research interests are production engineering, plasticity, nano/micromechanics, FEM and biomechanics.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Lee, HS., Park, SG., Hong, MP. et al. Process design of multi-stage cold forging with small size for ESC solenoid valve parts. J Mech Sci Technol 36, 359–370 (2022). https://doi.org/10.1007/s12206-021-1235-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-021-1235-3

Keywords

Search

Navigation