In selecting "KOREAN SICKLE" as the subject of study about process design, many factors were considered, such as increasing productivity, improving quality and reducing cost. The production rate was established at 100,000 pieces per year.
The length, width, and thickness of blade were designed to suit the strength requirements and material availability. It was advantageous in processing to give a specific radius R for the curvature of the blade. The hardness and toughness of blade were selected for wear resistance and shear characteristics.
In the die design, perfect nesting helped to simplify the die, to reduce the cost of die and press tonnage, and to increase the productivity in press working.
Heavy stock removal grinding was more economical than slab or end milling in rough forming of the blade cutting edge. A magnetic chuck is used to clamp the blade quickly for grinding.
Among hardening methods, induction hardening was the best one from the following points of view, workpiece distortion, cost, automation, and factory pollution. Progressive quenching was more effective than full length quenching with induction hardening.
In this product and process design study, efforts were concentrated on two points, improving the quality of blade, and minimizing production cost.
