;Recently the sheet forming simulation technology revealed great progress in the sense of practical application in the automotive, electric/electronics and aviation/space industries. The goal of sheet forming simulation is to embedded in the design engineering system which is consisted by the analysis and synthesis modules. This design simulation system predicts the slackness of sheet and estimate the formability, and search the optimum material/forming/structure conditions. This OVER-ALL OPTIMUM DESIGN can be classified as follow; 1. ANALYZING PROCEDURE: Numerical simulation based on nonlinear theories -geometry, material and friction nonlinearities- 2. OPTIMIZATION PROCEDURE: Optimum design based on mathematical programing and AI technologies, those are implemented in CAD/CAM/CAE System - Concurrent Engineering System-. In this paper, four subjects will be discussed; (1) State of arts of computer simulation technologies in Japan. (2)History of sheet forming simulation. (3) Benchmark problems. (4) Future technology in the sheet forming simulation.ation.

In metal forming, there ar problems with recurrent geometric characteristics and without explicitly prescribed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. The present study deals with nonsteady-state three-dimensional finite element analysis for extrusion of a trocoidal helical gear through a curved die. The boundary-directed remeshing scheme based on the modular remeshing technique is developed to reduce the errors arising in fitting old and new mesh systems. The computed extrusion pressure in reaching the near steady-state loading stage is compared with the results of the experiment and the steady-state analysis. The three-dimensional deformed pattern involving warping at the extruded end due to torsional deformation mode is demonstrated.

The study is concerned with the coupled analysis of heat transfer and thermoelastoplastic deformation. The thermoelastoplastic model is very useful for the analysis of residual stress and the analysis of thermal stress as well as the analysis of metal forming. Heat of deformation, phase transformation and contact heat transfer boundary are considered. The contact heat transfer boundary is treated by the interpolation of shape function. The analysis of deformation and the analysis of heat transfer are carried out for the could upsetting and the hot rolling. The computed results are found to be in good agreement with the experimental results.

For theoretical estimate of closed-die forging pressure, upper-bound method is applied to the involute tooth profile. In the analysis, the deformation regions have been divided into several zones. A constant frictional stress has been assumed on the contacting surfaces. Utilizing the formulated velocity fields, numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth and friction factor, on the forging of spur gears. Very close agreement was found between the predicted values of forging load and those obtained from experimental results.

An upper bound elemental technique(UBET) is applied to predict forging load and die-cavity filling for non-axisymmetric ring forging. The finial product is divided into three different deformation regions. That is axisymmetric part in corner, lateral plane-strain part and shear deformation on boundaries between them. The plane-strain and axisymmetric part are combinded by building block method. Also the total energy is computered through combination of three deformation part. Experiments have been carried out with pure plasticine billets at room temperature. The theoretical predictions of the forging load and the flow pattern are in good agreement with the experimental results.

Strip drawing of strain-hardening, viscoplastic materials with damage is analyzed by a rigid plastic finite element method. A process model is formulated using two state variables, one for strain hardening from slip dominated plastic distortion and the other for damage from growth of microvoids. Application of the model to steady state drawing is given via implementation in a consistent penalty finite element formulation. The predicted density changes as a result of void growth are compared to those from experiments reported in the literature. The effects of drawing conditions such as drawing speed and die angle on the mechanical property changes are studied.

This study aims detecting forming defects for the forming process of bearing rings, which is designed by an industry expert. The designed process consists of one forming operation for the outer ring and four operations for the inner ring. The thickness of the sheet used is 1.6mm, and is in between of thin sheet and bulk material. Here the rigid-plastic finite element method is applied to the analysis and design of the process without considering anisotropy of thin sheet. Thinning and folding defects are detected if the initially designed process is applied for manufacturing. so a new process is designed by referring the results of the FEM. It is confirmed that the industry expert agree the possibility of defects derived from FEM results.

Forming limit diagrams for three different galvanized deep drawing quality steel sheets have been measured by hemispherical punch stretching. The experimental forming limit diagrams have been compared with results calculated using the shear instability criterion and the M-K model which takes into account a strain gradient effect resulting from bending (curvature) of a flat sheet by punch stretching. The measured data were in good agreement with the results calculated using exponent M value of 8 in Hosford's yield criterion for the M-K model and M= 6 for the shear instability model.

The sheet perforated with a uniform triangular pattern of round holes and subjected to in-plane stress f arbitrary biaxiality was investigated. The equivalent continuum approach was employed to develop a theoretical model for global analysis, which includes defining a yield criterion and the strain hardening in terms of apparent stresses and apparent strains. Finit element analysis and experiment tension test were performed to examine the validity of proposed yield criterion and strain hardening models of perforated sheets.

This paper describes a method and a system for automatic generation of flanged cylinderical deep drawing process outlines. A process outline is a sequence of operation leading from the blank to the required finished part. The input is the dimension of final product and the output is the effective process outline to manufacture the product. That system is programmed by PROLOG language and is composed of facts and rules of manufacturing knowledge hierarchically.

The planar anisotropic FEM analysis for predicting the earing profiles and draw-in amounts in the deep-drawing processes is introduced. An implicit, incremental, updated Lagrangian formulation with a rigid-viscoplastic constitutive equation is employed. Contact and friction are considered through the mesh-based unit vectors and the normal contact pressure. the consistent full set of governing relations, comprising equilibrium and geometric constraint equations, is appropriately linearized. Barlat's strain-rate potential is employed, whose in-plane anisotropic properties are taken into account with anisotropic coefficients and potential parameter. The linear triangular membrane elements are used for depicting the formed sheet. with the numerical simulations of deep drawing processes of flat-top cylindrical cup for the 2090-T3 aluminum effects on the earing behavior are examined. Earing predictions made for the 2090-T3 aluminum alloy sheet show good agreement with experiments, although some discrepancies were observed in the directional trend of cup height and thickness strains.

Differential side bevel gears have been produced by machining process, but recently cold forging process for the bevel gear is under development in domestic industry. This study presents the possibility to form not only bevel gear but also spline gear at the same time using the experiment and numerical analysis. The preform shape is designed to form both bevel gear and spline gear simultaneously by the backward tracing scheme of the rigid-plastic finite element method(FEM). The experimental results confirm that the numerically-designed preform is satisfactory to form both bevel gear and spline gear. It is noted that the backward tracing scheme is helpful in designing preforms.

An experimental study on material characterization and mechanical properties of SMC(Sheet Molding Compounds) compression molding parts was carried out. Simple compression test using grease oil as a lubricant was carried out to characterize flow stress of SMC at elevated temperatures. Two different mold temperatures, 130$^{\circ}C$ and 150$^{\circ}C$ and two different mold speeds, 15, 45mm/min were used for preparing the specimen of SMC compression molding parts. Surface roughness, tensile, and 3-point bending tests were used to determine the effects of molding temperatures and speeds on mechanical properties of compression molded SMC parts.

Powder forged Connecting Rods have become attractive for use in automotive engines. The powder forging process offers beneficial material utilization as well as the minimization of finishing operations over that of conventionally forged rods. In the present work, the sintering behavior of Fe-2Cu-0.6C, optimum preform design and forgeability of various forging variables were investigated. Our data were generated using a newly proposed sub-scale con-rod developed specifically to simulate the powder forging process. We obtain optimum condition of sintering and powder forging process.

A constitutive model was proposed to analyze creep densification and grain growth of alumina powder compacts during high temperature processing. Theoretical results from the constitutive model were compared with various experimental data of alumina powder compacts in the literature including pressureless sintering, sinter forging and hot pressing. The proposed constitutive equations were implemented into finite element analysis program (ABAQUS) to simulate densification for more complicated geometry and loading conditions. High temperature forming processing of alumina compact with complicated shape was simulated. Processing of Alumina Powder Compacts

The creep behavior and creep fracture of alumina at high temperature were investigated under four point flexural test. The steady-state creep behavior was observed at low bending stress and the primary creep until fracture was observed at high bending stress. The loading history of bending stress did not affect on the steady-stated creep rate. Intergranular fracture was dominant for fracture of alumina at room and high temperature. However, transgranular fracture was dominant on creep fracture of alumina under high temperature by nuclueation and growth of microcracks due to residual flaws or cavities in the material.

Effect of some process variables including area reduction, stroke advance, materials on the extrusion load, plastic flow and height ratio of upper to lower extruded parts in the cup-cup axisymmetric extrusion were experimentally investigated and analyzed. Deformed pattern is visualized by grid-marking technique using half-cut billets splitted. The influence of using split specimen and original specimen on the extrusion load and height ratio is examined by experiment.

This paper suggests the scheme to simultaneously accomplish prediction of fracture initiation and analysis of deformation in metal forming processes. the Cockcroft-Latham criterion is used to estimate whether fracture occurs during the deformation process. The numerical predictions and experimental results of simple upsetting are compared. The proposed scheme successfully predicted the fracture initiation found experimentally.

The present study is concerned with the characteristics of the high speed precision bar cropping. This process is a practical application of High Energy Rate Forming in which the impact energy source is given by internal combustion engine. To enhance the added value of product, the recent forging fields trend toward the near net shape processes through the cold and closed die forging. For the purpose of these processes the precedent process is to obtain the precision billet which has little weight deviation and defect. The accuracy of initial billet by bar cropping depends upon the process parameters and die design technology. Therefore, in order to investigate the effect of process parameters upon product quality, the cropping experiments are carried out according to the various parameters such as billet clearence, billet length, billet material, cropping speed and so on. From these results some criteria of the optimal die design for the product of good quality are suggested.

The chassis of T.V, cassette, radio and telephone are made up thin-iron plates that makes a lot of female screws to assemble various parts. Then makes hole in the iron plate and forming female screws of burring face after the burring. Female screws forming in thin-iron plate is very difficult working then rolled forming process use of plastic deformation instead of cut forming. In this study goals are solve the trouble problem of industrial field and develop new model tap for prevent chips.