Analysis of Process Simulation and Rationalization of Precision Forming Dies

Founded in 2012, Hornjun Industrial Co., Ltd. is specialized in various metal forming mold manufacture, ranging from forging (hot, warm and cold) stamping (includes progressive dies) and die casting molds. The main equipments includes three sets of numerical controlled precision 4-axis/5-axis milling machines, Power Mill tool simulation software and a full range of measurement tools. + .However，Hornjun Industrial Co., Ltd. has faced a very severe challenges, mainly from mainland China, for mimicking and low-cost competition via the molds products at all costs. Therefore, desperate in need of help from the research and development using the latest technology as well as rationalization of in the metal forming mold making and process design analysis, in order to fully meet the highly competitive demand from all sorts of industrial sectors.In this proposal, rationalization of metal forming molds. process design and detailed tool design have been conducted systematically. To ensure the appropriateness of the suggested process with respect to deformation behavior, a 3dimensional finite element simulation (DEFORM) including metal forming load prediction is proposed and will be carried out, and experimental investigations are also performed using various metal materials (Carbon steels, aluminum, titanium alloys etc.) as the initial billet material. Emphasis is particularly placed on the rationalization of mold design. Pre-matured mold fracture failure of due to the improper process design and asymmetric geometry will be investigated. In response to mold modification of the die geometry, the structural integrity evaluation will be performed to achieve the dimensional accuracy at the critical cross sections of the metal forming parts. Results of mold life improvement will be systematically compared and recorded.