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초소형 스크류 온간 다단 헤딩공정 연구

장연희1, 정진환1, 장명근1, 홍재근2, 김종봉3,#

Design of a Multi-Step Warm Heading Process for Subminiature Screws

Yeon Hui Jang1, Jin Hwan Jeong1, Myung Guen Jang1, Jae-Keun Hong2, Jong-Bong Kim3,#
Journal of the Korean Society for Precision Engineering 2017;34(2):83-87.
Published online: February 1, 2017

1 서울과학기술대학교 자동차공학과

2 한국기계연구원 부설재료연구소 특수합금연구그룹

3 서울과학기술대학교 기계자동차공학과

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#Email: jbkim@seoultech.ac.kr, TEL: +82-2-970-6434, FAX: +82-2-979-7032
• Received: November 24, 2016   • Revised: January 1, 2017   • Accepted: January 16, 2017

Copyright © The Korean Society for Precision Engineering

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  • A multi-step warm forging process for subminiature screws is investigated. Due to the low formability of Titanium alloys, bit forming of Titanium screws is difficult by cold forging. In order to overcome this low formability of Titanium alloys, two candidate processes, i.e., multi-step forging and warm forging are introduced. First, a multi-step (two-step) forging process is investigated. The punch shape and stroke of forging during the first step is designed via various analyses. Finally, the bit formability is investigated at different forging temperatures. Analyses are carried out for two-step forging at various temperatures and the formability under these thermal conditions is compared.
  • KEYWORDS: Subminiature screw, Forging analysis, Finite element analysis, Warm forging
  • KEYWORDS: 초소형나사, 단조해석, 유한요소해석, 온간 단조
각종 전자기기의 소형화 및 경량화로 인해 부품의 소형화 개발 또한 요구되고 있다. 체결력 증가1-5와 풀림 방지6,7에 대한 연구뿐만 아니라 부품의 체결을 위한 소형화 나사에 대한 성형8-10에 대한 연구도 활발히 진행 중이다. 소형화 된 나사는 나사산 부위뿐만 아니라 단조 공정을 통해 성형된 헤드부의 성형성 검토가 필수적이다.
본 연구에서는 초소형 Titanium 나사의 머리부 성형성 개선에 대해 연구하였다.
단조는 원하는 형상의 다이 및 펀치로 소재에 압축하중을 가해 소성 변형을 일으켜 성형하는 공정으로 상온에서 이루어지는 냉간 단조, 고온에서의 온간 및 열간 단조법 등이 있다. 최근 단조 공정 시 발생되는 불량 및 헤드부의 단조 공정에 대한 연구들이 활발히 수행되었다.8-10 소형나사의 헤드부의 단조 성형 공정에 있어 가장 큰 문제가 되는 부분은 접힘 (Folding), 소재의 비충전으로 인한 형상 불량, 그리고 크랙 발생이다. 따라서 나사의 헤드부의 불량 개선을 위한 공정 설계가 필요하다.
Fig. 1은 Titanium Gr. 4 소재를 이용한 초소형 볼트의 머리부를 냉간 단조 시 발생한 불량 형상 예이다. Titanium 합금이 상온에서 성형성이 좋지 않기 때문에 접힘과 크랙이 발생하였다. Fig. 1의 불량은 Titanium Gr. 4 소재를 이용하여 상온에서 1단 단조 성형을 한 제품이다. 불량을 개선하기 위해 공정 개선이 필요함을 보여준다. 공정 개선을 위해 2가지 방법을 검토하였다. 첫째는 다단 성형이고, 둘째는 온간 성형이다. 다단 공정은 2단으로 구성하였고, 1단에서 예비 형상을, 2단에서 최종 형상을 성형하도록 구성하였다. Kim 등8은 스테인레스 볼트의 TORX 형상 비트 단조를 위해 다단 단조 공정을 설계하였다. 본 연구에서는 Titanium 소재의 볼트에 십자 (+) 형의 비트를 성형하는 것으로 새로운 공정의 설계가 필요하다.
Fig. 1

Examples of forming defects of subminiature titanium screws

KSPE_2017_v34n2_83_f001.jpg
본 연구에서는 최종 성형품의 손상도를 최소화하고 성형성을 증가시키기 위해 2단 성형 공정의 각 공정의 펀치 형상과 펀치 행정(스트로크)을 결정하였다. 성형성은 손상도와 접힘 결함을 고려하여 결정하였다. 상온에서 결정한 펀치 형상과 행정에 대해 온간 성형 특성을 검토하였다. 온간 성형에서는 각 온도별 손상도를 예측하여 온도에 대한 성형성을 상대적으로 비교해 온간 성형시 성형성을 검토하였다.
2.1 다단공정 구성 및 유한요소 모델
Fig. 2는 초소형 나사 단조 공정의 개략도이다. Fig. 2(a)는 초기 형상이고 Fig. 2(b)는 1차 공정 후 형상, 그리고 Fig. 1(c)는 2차 공정 후 최종 형상이다. 초기 소재의 길이 L0는 부피를 고려하여 2.15 mm로 결정하였다. 초기 선재의 직경은 0.68 mm 이다. 다단 단조 공정에서 설계 변수는 1차 공정의 펀치 행정 (Fig. 2의 L0 - L1)과 펀치 형상이다. Fig. 2(c)의 L2는 최종 형상에 의해 0.2 mm로 결정된다. Fig. 3은 1차 단조 공정에서 검토한 펀치 형상을 보여준다. 4가지 경우에 대해 해석을 진행하여 가장 성형성이 좋은 경우를 선정하였다.
Fig. 2

Configuration of the two-step head forging processes: (a) The initial billet, (b) The intermediate preform, (c) The final product

KSPE_2017_v34n2_83_f002.jpg
Fig. 3

Punch shapes for 1st preforming: (a) Model 1, (b) Model 2, (c) Model 3, (d) Model 4

KSPE_2017_v34n2_83_f003.jpg
소재는 Titanium Gr. 4로 응력-변형율 곡선을 인장시험을 통해서 구하여 사용하였다. Fig. 4는 시험한 인장시험 결과를 보여준다. 원소재를 냉간가공을 통해서 강도를 개선한 재료를 25도에서 시험한 결과 (CW_T25°C), 냉간가공 후 400°C에서 30분간 열처리한 소재를 25, 150, 200, 250도에서 시험한 결과 (각각 CW+HT_25°C, CW+HT_150°C, CW+HT_200°C, CW+HT_250°C)이다. Fig. 4에서 CW는 냉간가공을 HT는 열처리를 의미한다. 측정한 물성을 이용하여 단조 해석을 수행하였다.
Fig. 4

Stress-Strain curve of Titanium Gr. 4 at various temperatures

KSPE_2017_v34n2_83_f004.jpg
해석은 AFDEX 3D를 이용하여 수행하였고, 단조의 윤활조건을 고려하여 마찰계수는 0.05로 하여 해석을 진행하였다.10 해석은 격자 재구성을 통해서 변형율 및 형상 변화가 큰 부위에 충분히 작은 요소를 사용하여 수행하였다.
성형성은 접힘, 미충진, 그리고 손상도로 판단하였다. 접힘과 미충진 결함은 변형 형상으로 정성적으로 판단하였고, 손상도는 Cockcroft-Latham11 이론을 이용하였다. Cockcroft-Latham11 손상도는 다음과 같이 정의된다.
(1)
D=∫0ε¯σ1σ¯dε¯D0
식(1)에서 σ1은 주응력, σ는 유효응력, 그리고 D0는 임계 손상도이다. 임계 손상도는 인장시험 결과를 이용하여 결정하였다. 식(1)에서 손상도가 1.0 이상이면 크랙이 발생할 가능성이 있음을 의미한다.
2.2 임계손상도 결정
인장시험 해석을 통해서 임계손상도를 결정하였다. 해석은 AFDEX 3D에서 인장시험 해석 방법을 이용하였다. Fig. 5는 인장시험 후 소재의 형상을 보여준다. 파손이 발생하는 연신율과 단면감소율을 Table 1에 기술하였다. 냉간가공한 소재는 연신율이 약 16%이고, 열처리 후 150도에서 시험한 결과는 연신율이 23%이다. 단면 감소율도 열처리 후 고온 시험의 경우 더 크다. 시험에서 구한 파단 변위까지 인장시험 해석을 수행하여 결과를 분석하였다. Fig. 6은 인장시험 해석 후 변형 형상과 예측된 임계손상도를 보여준다. 예측된 임계손상도를 Table 1에 기술하였고, 식(1)에 적용하여 크랙 발생 가능성에 대해 뒤에서 분석하였다.
Fig. 5

Deformed shapes after tensile test: (a) CW_25°C, (b) CW+HT_25°C, (c) CW+HT_150°C, (d) CW+HT_200°C, (e) CW+HT_250°C

KSPE_2017_v34n2_83_f005.jpg
Table 1

Tensile test results and predicted critical damage

Table 1
Materials Elongation
(%)		 Area reduction
ratio (%)		 Critical
damage
CW_25°C 16 24 0.96
CW+HT_25°C 23 26 0.98
CW+HT_150°C 23 30 1.43
CW+HT_200°C 24 32 1.51
CW+HT_250°C 20 35 1.35
Fig. 6

Deformed shapes and predicted damage values after tensile test analysis: (a) CW_25°C, (b) CW+HT_25°C, (c) CW+HT_150°C, (d) CW+HT_200°C, (e) CW+HT_250°C

KSPE_2017_v34n2_83_f006.jpg
또한, 열처리 후 해석에서 예측된 단면 감소율은 Table 1에 기술된 4가지 경우에 대해 각각 27, 25.2, 30, 31, 35%로 시험결과와 거의 일치한 결과를 보였으며, 이를 토대로 해석의 본 논문에서 적용한 임계손상도 결정 방법의 신뢰성을 확인할 수 있다.
2.3 다단 단조공정 설계
1차 공정의 펀치 행정에 대한 해석을 수행하여 Fig. 2(b)의 L1을 결정하였다. L1이 2.15, 1.5, 1.0, 0.5 mm에 대해 해석을 수행하였다. L1이 2.15 mm인 경우는 2단 성형이 아니고 1단 성형이다. 본 해석에서는 1단 성형 펀치 형상이 Fig. 3에 보인 형상이 아니고, 평면 형상의 펀치를 이용하였다. Fig. 6에 최종 해석 결과를 도시하였다. 1단 성형인 Fig. 7(a)의 경우 ‘A’ 부분에서 접힘 결함이 발생하였다. L1이 1.5, 1.0 mm인 경우에는 Fig. 7(b)부터 7(c)의 ‘B’와 ‘C’ 부분에 미충진 결함이 발생하였다. L1이 0.5 mm인 경우에는 비교적 접힘 및 미충진 결함이 없는 결과를 보인다. 본 해석에서 1차 공정 후 L1은 0.5 mm로 결정하였다.
Fig. 7

Deformed shapes after final forging for various L1

KSPE_2017_v34n2_83_f007.jpg
L1에 대한 분석 후, 1차 공정의 펀치 형상에 대해 해석하였다. 1차 공정의 펀치 형상은 Fig. 3에 도시된 4가지 경우에 대해 해석하였다. Figs. 8부터 11은 Fig. 3에 보인 각각의 펀치 형상에 대해 해석한 결과를 보여준다. 1차 펀치 형상이 Model 1인 Fig. 8의 경우 1차 공정과 2차 공정에서 접힘 결함 (‘A’, ‘B’) 가 예측 되었고, 미충진 결함도 예측이 되었다 (‘C’).
Fig. 8

Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 1)

KSPE_2017_v34n2_83_f008.jpg
Fig. 9

Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 2)

KSPE_2017_v34n2_83_f009.jpg
Fig. 10

Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 3)

KSPE_2017_v34n2_83_f010.jpg
Fig. 11

Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 4)

KSPE_2017_v34n2_83_f011.jpg
1차 단조 펀치 형상이 Model 2인 Fig. 9의 경우 1차 공정에서 접힘 결함 (‘A’)과 2차 공정에서 미충진 결함 (‘C’)은 개선 되었지만, 2차 공정에서 접힘 결함 (‘B’)는 여전히 개선되지 않고 있다. Model 1과 Model 2는 L1이 0.5 mm 이지만, Model 3과 Model 4는 펀치 길이가 짧아졌기 때문에 L1을 0.6 mm로 하였다. Fig. 10에 보인 Model 3의 경우도 2차 공정에서 접힘 결함 (‘B’)이 개선이 되지 않고 있다. Model 4의 경우인 Fig. 11에서는 접힘 및 미충진 결함이 없어지고 잘 성형이 됨을 알 수 있다. 이 결과를 바탕으로 1차 공정에서 L1은 0.6 mm, 1차 공정의 펀치 형상은 Model 4로 결정하였다.
3.1 파손모델 계수 결정을 위한 인장시험
냉간에서 설계한 다단 단조 공정으로 온간 성형에 대해 해석을 수행하였다. 각 온도 조건에서 응력-변형율 선도를 Fig. 4에 도시한 실험 결과를 이용하였다. Fig. 4에 도시한 재료와 성형 온도 조건에 대한 해석 결과를 Fig. 12에 도시하였다. 볼트의 위와 정면에서 본 손상도 분포이다. 도시된 손상도는 인장시험 해석에서 구한 임계손상도를 식(1) 이용하여 구한 값이다. Figs. 12(a)부터 12(e) 모든 경우에서 손상도는 1을 넘지 않는다. 엄격하게 분석하면 모든 경우에서 크랙이 발생하지 않는다는 의미이다. 하지만, Cockcroft-Latham 손상 모델은 인장에서의 파손과 압축에서의 파손에 대한 고려가 부족하고, 압력 등의 다른 인자에 대한 고려가 없기 때문에 절대적 의미에서 분석하기는 힘들다. 보다 정확하게 절대값의 의미를 가지기 위해서는 임계손상도를 압축시험에서도 구해서 사용해야 한다. 그래서, 본 연구에서는 상대적인 의미로만 분석을 하고자 한다. Table 2에 해석으로 예측한 최대 손상도를 요약하여 기술하였다. 가공경화된 재료의 상온 성형 (CW_25°C)의 경우 손상도가 가장 큰 0.75가 예측이 되었다. 가공경화된 재료를 열처리하여 상온에서 시험한 경우 (CW+HT_25°C)에는 손상도가 다소 줄기는 했지만 여전히 0.69가 예측이 되었다. 열처리에 의해 연신율은 크게 증가했지만 손상도가 크게 줄지 않은 이유는 임계손상도 값이 증가하지 않았기 때문이다 (Table 1). 열처리에 의해 균일 연신율을 증가했지만, 궁극적으로 파손을 결정하는 파손에서의 최대 국부 변형율은 크게 증가하지 않았기 때문으로 사료된다. 파손시 최대 변형율은 전연신 보다는 단면 수축율에 가깝다고 볼 수 있다. 열처리에 의해 단면 수축율이 미미하게 증가했다 (Table 1).
Fig. 12

Deformed shapes and predicted damage after final forging for various temperatures: (a) CW_25°C, (b) CW+HT_25°C, (c) CW+HT_150°C, (d) CW+HT_200°C, (e) CW+HT_250°C

KSPE_2017_v34n2_83_f012.jpg
Table 2

Maximum normalized damage values for various forming temperatures

Table 2
Materials and forging
temperature		 Normalized
damage
CW_25 C 0.75
CW+HT_25°C 0.69
CW+HT_150°C 0.50
CW+HT_200°C 0.47
CW+HT_250°C 0.53
온간 성형 해석 결과인 Figs. 12(c)부터 12(e)에서는 최대 손상도가 약 0.5이다. 이것은 단면 수축율이 150, 200, 250°C에서 30 - 35%로 증가했기 때문으로 사료된다. 결과적으로 최대 손상도는 연신율보다는 단면 수축율에 의해 결정이 되고, 온간 성형에서는 단면 수축율이 크기 때문에 손상도가 낮게 예측이 됨을 알 수 있다. 이것은 파손 시점에 파손 부위의 국부 변형율이 파손에 관계되기 때문으로 사료된다. Fig. 12와 Table 2에서 손상도가 가장 작은 경우는 200°C에서 성형한 경우임을 알 수 있다.
본 연구에서는 초소형 나사의 헤드부 단조 성형 과정에서 발생하는 접힘 현상 및 공정 펀치 형상에 따른 성형성과 손상도를 분석했다. 난성형재인 Titanium Gr. 4 에 대해 1단 단조시험 결과 성형이 불가능하였다. 성형성 개선을 위해 2단 단조 공정을 설계하였고, 온간 성형도 분석을 하였다.
2단 단조 공정에서 접힘 및 미충진 불량이 없이 성형 가능한 공정변수와 펀치 형상을 설계하였다. 설계된 2단 단조 공정으로 상온, 150, 200, 250도에서 단조를 해석하여 성형성을 분석하였다. 200도에서 2단 단조할 경우 손상도가 가장 작게 예측됨을 알 수 있었다.
본 연구는 산업통상자원부 산업기술혁신산업(우수기술연구센터산업, 과제번호: 10045724)의 지원으로 수행된 연구임.
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Design of a Multi-Step Warm Heading Process for Subminiature Screws
J. Korean Soc. Precis. Eng.. 2017;34(2):83-87.   Published online February 1, 2017
DOI: https://doi.org/10.7736/KSPE.2017.34.2.83
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Design of a Multi-Step Warm Heading Process for Subminiature Screws
J. Korean Soc. Precis. Eng.. 2017;34(2):83-87.   Published online February 1, 2017
DOI: https://doi.org/10.7736/KSPE.2017.34.2.83
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Design of a Multi-Step Warm Heading Process for Subminiature Screws
Image Image Image Image Image Image Image Image Image Image Image Image
Fig. 1 Examples of forming defects of subminiature titanium screws
Fig. 2 Configuration of the two-step head forging processes: (a) The initial billet, (b) The intermediate preform, (c) The final product
Fig. 3 Punch shapes for 1st preforming: (a) Model 1, (b) Model 2, (c) Model 3, (d) Model 4
Fig. 4 Stress-Strain curve of Titanium Gr. 4 at various temperatures
Fig. 5 Deformed shapes after tensile test: (a) CW_25°C, (b) CW+HT_25°C, (c) CW+HT_150°C, (d) CW+HT_200°C, (e) CW+HT_250°C
Fig. 6 Deformed shapes and predicted damage values after tensile test analysis: (a) CW_25°C, (b) CW+HT_25°C, (c) CW+HT_150°C, (d) CW+HT_200°C, (e) CW+HT_250°C
Fig. 7 Deformed shapes after final forging for various L1
Fig. 8 Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 1)
Fig. 9 Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 2)
Fig. 10 Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 3)
Fig. 11 Deformed shapes during and final 1st and 2nd forging (1st forging punch: Model 4)
Fig. 12 Deformed shapes and predicted damage after final forging for various temperatures: (a) CW_25°C, (b) CW+HT_25°C, (c) CW+HT_150°C, (d) CW+HT_200°C, (e) CW+HT_250°C

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Fig. 10

Fig. 11

Fig. 12

Design of a Multi-Step Warm Heading Process for Subminiature Screws

Tensile test results and predicted critical damage

Materials Elongation
(%)		 Area reduction
ratio (%)		 Critical
damage
CW_25°C 16 24 0.96
CW+HT_25°C 23 26 0.98
CW+HT_150°C 23 30 1.43
CW+HT_200°C 24 32 1.51
CW+HT_250°C 20 35 1.35

Maximum normalized damage values for various forming temperatures

Materials and forging
temperature		 Normalized
damage
CW_25 C 0.75
CW+HT_25°C 0.69
CW+HT_150°C 0.50
CW+HT_200°C 0.47
CW+HT_250°C 0.53
Table 1 Tensile test results and predicted critical damage
Table 2 Maximum normalized damage values for various forming temperatures

Table 1

Table 2

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