Design of precise forming method that can implement highly advanced and accurate forging

Sindo High Tech Co.,Ltd. (Ho-gwon Seo, CEO)
Sindo High Tech Co., Ltd., a company specialized in the forging of automobile components such as inner pipe and inner sleeve, has maintained its existence as a front-runner for cold forging products in Daegu region by concentrating on cold forging over the past 30 years. Sindo High Tech, now focusing on higher value-added components and hybrid automobile components, has 60~80% of domestic market share with dominant cost-competitiveness and superior quality using cold multi-former, and is trying to strengthen its technical competitiveness to pioneer overseas routes.

Securing fabrication process technology for highly

competitive superior components The suspension, connecting the axle and body of a car, prevents damage to the body and the load and improves the impression of riding by enabling the axle not to deliver the impact from the road directly to the car body. Currently developed products include bushing that can be assembled with RR MBR Knuckle and other parts in the suspension and it is mainly used as a component that can influence wheel alignment as well as reduce vibration generated during operation. It is being used in GM global automobile, and its demand is expected to be increasing as the application will be extended to newly developed models. Thus, in compliance with consistent needs for high reliability, Sindo High Tech carried forward component development showing high reliability.
Existing fabrication processes are composed of a total of three steps where all components are made individually and then welded, which is very wasteful for materials, requires much energy-use in the manufacturing, and there is great concern about defective forming in welding or damage in the neck area. In order to improve such flaws, parts fabrication processes were developed through this research task; making precise forming with cold multi-former and forming the shape after removing stress from the materials and surface treatment, which consequently reduced the processes dramatically. Moreover, developing technology that can manufacture parts economically having not just high yield but also superiority in terms of characteristics allows securing competitiveness.
In this regard, Ho-gwon Seo, CEO of Sindo High Tech Co.,Ltd explained, “After designing dies for each process based on developed process blueprint, we had to undergo many trials and errors because we could not have expected results in the course of manufacturing actual dies through feasibility study and testing trial produces due to many causes. We made steady and persistent efforts to improve program interpretation and mold design technique based on the results from such trial and error, and finally could solve the problems by the aid of cooperative organizations.”

Development of integral ROD-A by securing four core element technologies

In existing production processes for ROD-A, hole unit and circular unit were produced separately and passed through thewelding process before being supplied as a component.
However, that process was so wasteful for materials that there was a problem that reduces productivity and durability significantly in the welding process of making separated parts into one integral component. In order to solve this problem, Sindo High Tech developed integral ROD-A for final shape forming using primary product forming and high load press through cold multiformer. The first core technology is cold extrusion multi-forging method and mold design technology. It is possible to design a method that considers forming volume and forming energy for each step and molds for which dimension changes caused by elastic recovery in the molds and the materials are considered. The second core technology is forming interpreting technique based on the finite element method. Based on the finite element method, it is possible to have techniques for breaking prediction and coupled analysis, considering flow stress in materials interpreting the forming and using damage models. The third core technology is the optimization of forming process parameters and micro-structure control in raw material. Forming features for raw materials can be secured through the optimization of load-deformation, metal flow characteristics, stress & distortion, and energy distribution, and spheroidized annealing process optimization. The fourth is technology of securing mold durability.

It can lubricate the mold, extend the service life with heat and surface treatment, and minimize damage through stress interpretation. Trial products were manufactured based on such core element technologies, and final improvement could be made through characteristic evaluation. Also, mass- production technique could be secured through standardization, and industrialization could succeed.
CEO Mr. Seo who suggested that competitiveness, highdefinition, and high-quality is required for current core components in the world’s automobile industry explained that ”
Especially, demands for weight- reduction and cost-reduction keep on increasing to overcome resources, energy-saving, and environment issues in automobile industry. In accordance with such needs of the times, Sindo High Tech has developed new fabrication processes that allow more cost savings than existing processes and new markets, which result in increase in annual sales. Because processes that can reduce CO2 generation from
production processes are required according to strengthened international environmental regulations, the business is very promising in future.”

The world’s first acquisition of a patent regarding precise forming method in Korea and abroad

In this country, trailing arm bush used in Hyundai-Kia Motors relies on welding by press forging, and automation facility is insufficient due to high-priced facility investment. In addition, studies for optimal forming conditions are so insufficient that our technical power is more than 10 years behind compared to Japan. For the overseas forging industry in advanced countries (specifically, the USA, Japan, and Germany), forging simulation is commonly used in process design. Even China, that has more outdated technology now than our country, would catch up the technology 4~5 years later and become a considerable threat to us. However, material utilization and performance improvement and studies on cost saving are consistently being progressed now mainly by local small and medium-sized cold forging companies. Most of all, automobile component business is developed in Daegu, and the former cold forging field is specialized in the new forging industry. In this regard, Sindo High Tech possesses many patents for new cold forging processes, and especially it is expected to acquire a patent for its precise forming method for the first time worldwide as a part of performance from this research task.

Representative patents related to such technical development include the automobile mounting pipe manufacturing method (Sindo High Tech Co.,Ltd., registration no. 1009089190000). This is about mounting pipe manufacturing that plays a supportive role to install other parts, and characterized by strong and efficient manufacturing even with simpler process than existing process.

In addition to this, the cylindrical bushing manufacturing method (Sindo High Tech Co.,Ltd., registration no. 1007811420000) can produce completed product of cylindrical bushing having fringe in both sides using multi-former, which allows remarkably improved production speed and saves manufacturing costs. | Blog Magazine of korean-machinery, brands and Goods

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