Shearing including punching, blanking, trimming, slitting, etc is one of the most frequently used processes in sheet metal manufacturing. It has been widely using for manufacturing autobody, electronic components, aircraftbody, etc. In this paper, it has been researched by the experimental investigation to examine the influence of shearing processes parameters such as clearance, cutting angle, material properties, etc. From the results of experiment, it has shown that it gives the small variations at burr height below the proper clearance and it also presents that it is no affected the variations of cutting angle.

The deformation behaviors of fully annealed or T6-treated 6061 and 7075 aluminum tubes are investigated at elevated temperature using uniaxial tensile test. Fully annealed 6061 and 7075 tube, and T6-treated 7075 tube do not show sharp local necking with an elongation of $50\%$ at tensile temperature of $300^{\circ}C$, accordingly, it is expected that warm hydroforming process can be applied. The increase of tensile temperature does not significantly affect the total elongation of T6-treated 6061 tube.

A bumper comprises a bumper face, a bumper beam for distributing the load from the impacts applied to the bumper face and reinforcing the bumper, an absorber member interposed between the bumper face and the bumper beam, and a pair of bumper stays which secure the bumper beam to the vehicle body. A conventional bumper stay structure is assembled into several stamped parts, so several processes are needed and the structure is complicated. In this study the bumper stay is applied to the tubular hydroforming which is known to have several advantages such as the reduction of the number of the process and the part weight. The thickness distribution of the tube is mainly considered to evaluate the hydro-formability and the shape of the tube is determined.

The development of automotive rear chassis part using tube forming process has advantage of increase in part durability and decrease in its weight. We developed tubular type rear CTBA(Coupled Torsion Beam Axle) part with 60K high strength steel developed by POSCO in this project. The result was demonstrated that tubular type CTBA shows excellent durability performance and $10\%$ weight reduction compared with V-beam type CTBA in our work. Furthermore, we will adapt this technology to mass production and apply to the other chassis parts.

Glass molding is an advantageous method to manufacture glass micro optical components. However, it is difficult to make Tungsten Carbide core for glass microlens array. We have developed novel method to fabricate Tungsten Carbide core for micro glass components using pressure forming. Silicon masters were fabricated by micro machining. Tungsten Carbide core was fabricated by pressure forming and sintering. And we made high quality surface of Tungsten Carbide core by using the magnetic-field-assisted polishing process.

Stamps for microcontact processing are fabricated by casting elastomer such as PDMS on a master with a negative of the desired pattern. After curing, the PDMS stamp is peeled away from the master and exposed to a solution of ink and then dried. Transfer of the ink from the PDMS stamp to the substrate occurs during a brief contact between stamp and substrate. Generally, negative-tone masters, which are used for making positive-tone PDMS stamps, are fabricated by using photolithographic technique. The shortcomings of photolithography are a relative high-cost process and require extensive processing time and heavy capital investment to build and maintain the fabrication facilities. The goal of this study is to fabricate a negative-tone master by using Nano-indenter based patterning technique. Various sizes of V-grooves and U-groove were fabricated by using the combination of nanoscratch and HF isotropic etching technique. An achieved negative-tone structure was used as a master in the PDMS replica molding process to fabricate a positive-tone PDMS stamp.

Although bulk metallic glasses have many outstanding aspects in their chemical, mechanical or functional properties, some critical problems still hinder their wide application. The most important one is the brittle nature of them, which is the serious problem to structural application. So, to use viscous flow is now the only competent way to form bulk metallic glass. In this study, we investigated the basic nature of viscous flow of Zr-base bulk metallic glass, vitrelloy 1, in terms of process variables. The results were used to design the thermo-mechanical process composed of heating, holding, pressing, and cooling, which have unique influence on the glass transition and crystallization behavior. We adopted small load scale and dies with nano/micro patterns on them. The results were evaluated using several analytical methods.

Injection molded plastic parts have many surface defcts: Warpage, wedline, flowmark, zetting, scratching, shading and so on. In the desktop mnitor's case, Weld line have been one of the main surface defects. Nowadays in the pursuit of light weight of parts, one of the big problems of LCD Monitor thinks Warpage and surface shrinkage. In this paper, we introduce some instances for prevevting these defestcs in the side of mould drawing, parts drawing and processing condition. Based on these, we tried to find out the optimum processing conditions through repeatedly tried injection moulding after reflecting these instances.

Almost all injection molds have multi-cavity runner for mass production, which are designed with geometrically balanced runner system in order to minimize filling imbalance between cavity to cavity during processing. However, even though geometrically balanced runner is used, filling imbalances have sometimes been observed. These filling imbalances have historically been considered as result of uneven mold temperature and mold deflection, but it actually results from non-symmetrically shear, pressure, temperature distribution within melt material as it flows through the runner system. Filling imbalance could be decreased by modifying processing conditions that are related to shear, pressure, temperature such as injection rate, mold temperature, injection pressure, melt temperature. In this study, a series of experiment was conducted using Taguchi method to determine which processing condition influence as the primary cause of filling imbalance in geometrically balanced runner system. As a result of experiments, this paper could present an optimal processing condition to minimize variable that brings about filling imbalance geometrically balanced runner system

The shrinkages of injection molded parts are different in molding operational conditions, resins and additives. The shrinkage of injection molded part for crystalline polymer, PBT (polybutylene terephthalate) has been studied for various operational conditions of injection molding and content of additives. Mica was used as a additive to PBT to examine the part shrinkage according to the mica content. The part shrinkages of mica contained PBT decreased as mica content increases. Higher injection temperature and injection pressure resulted in a lower shrinkage. As mold temperature increases the part shrinkage decreased. The part shrinkage of flow direction was less than that of the perpendicular direction to the flow for both pure and mica contained PBT. However the shrinkage difference between flow and perpendicular to flow directions decreased as mica content increased.

A computer code was developed to simulate the filling stage of the injection/compression molding process by a finite element method. The constitutive equation used here was the compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Simulations of a disk part under different processing conditions including the variation of compression stroke and compression speed were carried out to understand their effects on flow-induced birefringence. The simulated results were also compared with those by conventional injection molding and with experimental data from literature.

Pressure and temperature in the cavity of injection molding have been investigated. Special injection mold was designed to install pressure and temperature sensors. The sensors were supplied by KISTLER and the pressure and temperature were measured for various operational conditions, such as injection pressure, holding pressure, cooling time, mold temperature, and injection temperature. As injection pressure increased cavity pressure and temperature increase. There were no big differences in temperatures according to the holding pressures. As mold temperature increased pressure and temperature in the cavity increase. The flowability of resin increases as mold temperature increases subsequently the pressure in the cavity increases since the pressure loss is less in the low viscous medium than high ciscous medium. The cavity temperature highly depends upon mold temperature.

A mesh generation algorithm adapted to the mesh density map using the Delaunay mesh generation technique is developed. In the finite element analyses of the forging processes, the numerical error increases as the process goes on because of discrete property of the finite elements or severe distortion of elements. Especially, in the region where stresses and strains are concentrated, the numerical discretization error will be highly increased. However, it is too time consuming to use a uniformly fine mesh in the whole domain to reduce the expected numerical error. Therefore, it is necessary to construct locally refined mesh at the region where the error is concentrated such as at the die corner. In this study, the point insertion algorithm is used and the mesh size is controlled by moving nodes to optimized positions according to a mesh density map constructed with a posteriori error estimation. An optimization technique is adopted to obtain a good position of nodes. And optimized smoothing techniques are also adopted to have smooth distribution of the mesh and improve the mesh element quality.

In this study, a new refinement technique for 3-dimensional hexahedral element mesh is proposed, which is aimed at the control of mesh density. With the proposed scheme the mesh is refined adaptively to the elemental error which is estimated by 'a posteriori' error estimator based on the energy norm. A desired accuracy of an analysis i.e. a limit of error defines the new desired mesh density map on the current mesh. To obtain the desired mesh density, the refinement procedure is repeated iteratively until no more elements to be refined exist. In the algorithm, at first the regions of mesh to be refined are defined and, then, the zero-thickness element layers are inserted into the interfaces between the regions. All the meshes in the regions, in which the zero-thickness layers are inserted, are to be regularized in order to improve the shape of the slender elements on the interfaces. This algorithm is tested on a simple shape of 2-d quadrilateral element mesh and 3-d hexahedral element mesh. A numerical example of elastic deformation of a plate with a hole shows the effectiveness of the proposed refinement scheme.

Micro wires manufactured by the straightening progress are widely used in bio-medical and semi-conductor fields. In this study, we have developed a novel straightener which uses the direct heating method for straightening. In order to avoid the surface oxidization, during the heating process, we supplied the inert gas(Ar) and examined the effect of the gas flow rate. The effect of the tension and the current applied to the tungsten micro wires were thoroughly studied. From various experiments, it was found that when the tension is $500{\sim}600gf$ and the current is about 1.5A, we obtained higher straightness(${\approx}1{\mu}m/1000{\mu}m$) and roundness ($<{\pm}2{\mu}m/100{\mu}m$).

This paper is concerned with the drawing process of Al-Si wire. In this study, the finite-element model established in previous work was used to analyze the effects of various forming parameters, which included the reduction in area, the semi-die angle, the aspect ratio and the inter-particle spacing of the Si in drawing processes. The finite-element results gave the consolidation condition. From the results of analysis, the effects of each forming parameter were determined. It is possible to obtain the important basic data which can be guaranteed in the fracture prevention of Al-Si wire by using FEM simulation.

This paper presents a study on defects in pearlite lamella structure of high carbon steel by means of finite-element method(FEM) simulation. High-carbon pearlite steel wire is characterized by its nano-sized microstructure feature of alternation ferrite and cementite. The likely fatigue crack is located on interface of the lamella structure where the maximum amplitude of the longitudinal shear stress and transverse shear stress was calculated during cyclic loading. The FEM is proposed for maximum shear stress from loading of lamella structure, and a method is predicted to analyze the likely fatigue crack generation. It is possible to obtain the important basic data which can be guaranteed in the ductility of high carbon steel wire by using FEM simulation.

In rheo forming process, slurry making is very important factor because the microstructure of slurry affects the quality of final products. To control the microstructure of slurry, slurry making by new rheo die casting was studied. In new rheocasting method, processes parameters are degree of overheat in molten metal, cooling condition, high frequency induction heating condition and cup temperature. Microstructures according to these parameters were observed. By image analysis, equivalent diameter and roundness of grain were investigated and discussed. To find out mechanical properties of grain controlled aluminum part by rheo die casting, tensile tests were carried out to the T6 heat treatment.

The new rheology fabrication process has been developed to rheo die casting and rheo forming process. Thixoforming process has disadvantages in terms of induction reheating process, scrap recycling, loss of raw material and cycle time. Therefore, to reduce the number of process, new rheology fabrication process with specially designed the rotational barrel type equipment has been proposed to apply in various part productions. The barrel type equipment, which could continuously fabricate the rheology materil, was specially designed to have a function to control cooling rate, shear rate and temperature. During the continuous rotation of barrel with a constant temperature, the shear rate is controlled with the rotation speed. The barrel surface has both the induction heating system and the cooling system to control the temperature of molten metal. By using this system, the effect of the rotation speed and the rotation time on the microstructure was widely examined. The possibility for the rheoforming process was investigated with microstructural characteristic.

Application of aluminum alloy has been increasing for most of industry area because aluminum has a good mechanical properties and castability, especially automotive field for weight reduction. But, Furnace industry is sluggish. The purpose of this study is numerical analysis of aluminum holding furnace for reasonableness estimation when we design for new model of furnace. The numerical simulation involving fluid flow of inside air and heat transfer to fireproof material is presented in order to improve the understanding of aluminum furnace. First of all, we are carried out numerically for the two dimensional inside convection and surface radiation heat transfer in a square enclosure. Subsequently, we are established the analysis method of aluminum furnace considering natural convective heat transfer

It is many devices to obtain the globular structure because the globularity of the structure is the key to the low apparent viscosity and also to good rheological properties. In this study, the morphology of the change of primary Al phase in A356 alloy by electro magnetic stirrer was investigated to obtain the globular structure. The parameters are the current, stirring time, pouring temperature individually. The greater current and longer stirring time was to get the finer the primary however in case of over the 80A of current and 60sec of stirring time, the primary Al was merged together and was increased. The effect of pouring temperature has an important effect on the size of primary phase. About the $675^{\circ}C$, the primary Al was very fined.

In the extrusion process, the working material is forced to flow through a die with the desired profile. In general, the width of an extruded section is limited to about an inch less than the diameter of the round billet. But through the lip die, material is spreaded to produce a wider extruded section than the diameter of round billet. In this study, the extrusion process of an aluminum plate using the lip die is investigated. The width of the extruded plate is 450mm that is formed from the round billet with a diameter of 250mm. The flow characteristic through the lip die is considered to produce the wide-extruded plate with a small billet using rigid plastic FE analysis. Based on the result of FE analysis, an optimized design of the lip die is then proposed.

The bending phenomenon has been known to be occurred by the difference of velocity at the die exit. The difference of velocity at the die exit section can be obtained by the different velocity of billets inside die chamber after passing the multi-hole container. The curvature can be controlled by the two variables, the one of them is the different velocity of billets through the multi-hole container, the other is the difference of hole diameter. The bending phenomenon during extruding using four billets can be obtained by the difference of hole diameters in the multi-hole container or by the difference of relative velocity of billet inserted in the container. As results of DEFORM-3D analysis, it can be shown that bending can be obtained during extruding by the difference of relative velocity of two billets or by the difference of hole diameter, and the amount of curvature is increased by the difference of velocity and diameter. According to the shape of products, the curvature of rectangular section is bigger than the curvature of regular square section. And, it is estimated that, because the stress on the welding line is much higher than yield stress of material, the bonding of four billets can be obtained.

In the previous experimental study about extrusion of circular product with four helical fins, it was known that product with helical fins may not to be rotated during extruding with rotating extrusion dies in spite of using twisted dies. According to the results of experiments with Plasticin material, it was anticipated that the extrusion load could be reduced if rotating dies could be used, because it needs high pressure in order to twist billet and form fin shape on the surface of product in the case of using conventional fixed helical dies. So, in this paper, according to the extrusion load analyzed by DEFORM-3D software, optimal rotational velocity of rotating dies can be obtained, and the twisting, angle of product can be analyzed during extruding product with helical fins in the case of two types of rotating of dies. The results of analysis by DEFORM-3D show that the twisting angle of product can be controlled by twisted angle of extrusion helical dies and the rotational velocity of helical dies.

Magnesium alloys are being extensively used in weight-saving applications and as a potential replacement for plastics in electronic and computer applications. Magnesium alloy has some good characteristics, EMI shielding property and high specific strength. Nevertheless their high brittleness make it uneasy to process the magnesium. Magnesium alloys are extruded like aluminium alloys. The present work was done to find a characteristic of magnesium alloy(AZ31) changing the extrusion ratio 8.5, 19.1, 49 respectly and changing the die half angle $30^{\circ},\;45^{\circ},\;60^{\circ}$. Here this present done by the hydrostatic extrusion in the hot condition, $310^{\circ}$. The higher the extrusion ratio goes, the higher the extrusion force goes.

In order to reduce automobile parts weight, TWB(Tailored welded blank) forming is widely used in the forming of car panel, such as door inner, side outer panels. In this study, one of the current problems of TWB forming was analyzed, especially for the try-out process of TWB door inner panel without frame. A comparison was made between actual panel measurements and results of forming analysis for formability and springback.

Finite element method is very effective method to simulate the forming processes with good prediction of the deformation behaviour. For the finite element modeling of sheet mental forming the accurate tool model is required. Due to the geometrical complexity of real-size part stamping tools it is hard to make FE model for real-size auto-body stamping parts. In this paper, it was focussed on the drawability factors on auto-body panel stamping by AUTOFORM with using tool planing alloy to reduce law price as well as high precision from Design Optimization of die. According to this study, the results of simulation will give engineers good information to access the Design Optimization of die.

The aluminum tube hydroforming is a manufacturing process which can provide lightweight components as automotive parts. In this paper, the hydroformability of aluminium tube in different condition of bending process is presented. An investigation has been conducted on how to control the deformed shape and its effect on thinning distribution after hydroforming by using finite element simulation. Finite element simulation of tube hydroforming for automotive trailing arm is carried out to explore the effect of 2-dimensional and 3-dimensional bending.

Different kinds of feedstock of semisolid a356 aluminum alloy manufactured by EMS stirring only, inoculation of Al-5Ti-B only and combination of inoculation and EMS stirring were investigated. It is found that the grain size of these feedstock are $350{\mu}m$ for EMS casting only, $320{\mu}m$ for inoculation by Al-5Ti-B, and $100{\mu}m$ for the combination of EMS stirring and inoculation of Al-5Ti-B master alloys. The microstructure of the sample obtain by combination of inoculation and EMS system show the best homogeneousness and finest grains.

In the semi-solid die casting process, the important thing is the flow behaviors of semi-solid material. The flow patterns of semi-solid material can make the defects during die filling. To control of the flow patterns, is very important and difficult. In this paper, the flow behaviors of the semi-solid A356 alloy material during die filling at various die gate shapes has been observed with the grain size controlled material. The effects of the gate shape on the die filling characteristics were investigated. The filling tests in each plunger strokes were experimented, also simulated on the semi-solid material die casting process by MAGMAsofi. According to the filling tests and computer simulation, the effect of the gate shape on liquid segregation had been investigated.

Most formulations for a forming limit diagram (FLD) have been based on yield stress potentials defined in the stress field. Nevertheless, there are formulations where potentials defined in the stain-rate field are especially convenient to formulate the rigid plastic material. Based on a strain-rate potential proposed for materials exhibiting planar anisotropic, the formulations for the forming limit diagram has been developed applying M-K theory. As verification example, the formulation is applied for anisotropic AA5182-O sheet. The good verification results show that the formulation for the forming limit diagram has been successfully developed.

The hub hole in a wheel of vehicles usually formed with hole expansion process. Formability of material, especially the hole expansion ratio, is important to produce a fine hub hole. The hub hole expansion process is different from general forming process or bore expansion process in the viewpoint of forming a thick plate. In the hole expansion process of the plate with a hole, as the hole being expanded, the crack is occurred to outward direction at the boundary of a hole. Therefore, it is need to apply the fracture criterion in the hub hole expansion process. In this paper, the hub hole expansion process is simulated with commercial elasto-plastic finite element code, LS-DYNA3D considering some ductile fracture criteria. Fracture mode and hole expansion ratio is compared with respect to the fracture criteria. Analysis results demonstrate that only the effective plastic strain is not adequate to predict the fracture mode in the hub hole. And the analysis results also indicate that the ductile fracture criteria properly predict the fracture mode but hole expansion ratio is different with the result of each other because of their different characteristics.

The draw, trim, flange, and cam forming processes of automotive fender panel are simulated, focused on the springbacks. Simulation results are compared with field try-out. In order to compensate the differences between simulation and try-out, the draw bead shapes in the simulation are modified and the accuracy of the simulation is improved by comparing blank draw-in amounts. The spring-backs after formings are also found in the simulation. Finally, the simulation procedures for analyzing the springbacks in all stamping processes are established.

Superalloys with many strengthening alloying elements are frequently used in powder form to alleviate harmful effects of alloy segregation. HIP (hot isostatic pressing) and DB (diffusion bonding) as a form of solid-state bonding process is often used to make turbine components, such as integrated turbine rotors. HIP/DB process requires many technical overcomes related to dimensional changes as well as microstructural control. In this research, HIP/DB process for nickel base superalloys, Udimet 720, were investigated with a view to control the dimensional change during the consolidation process. Simple disc-shaped cans were used to select the conceptual die design for the control of the dimensional change especially in radial direction. The change in the shape of consolidated shape was investigated using commercial FE code with constitutive equations for low temperature plasticity and creep deformation.

Since the formability of AZ31 magnesium alloy is not good in room temperature, it is known that high temperature forming is advantageous. However, many studies are necessary to find the proper forming temperature for Mg alloy. In this study, experimental and FEM analysis are performed to investigate the forming temperature for AZ31 sheet. The deep drawing process of square cup is used in forming experiment and FEA. The investigations are performed in three forming temperature, room temperature, $250^{\circ}C\;and\;400^{\circ}C$. The square cup is well formed in $250^{\circ}C$ forming temperature, on the other hand, the crack and failure is presented in corner section in room and $250^{\circ}C$ forming temperature. The main cause is investigated as the effect of hardening range by the experimental and FEM results.

Superplastic formability depends on flow parameters such as temperature, strain rate, strain and stress, microstructures. Usually, superplastic properties of materials are characterized with using a uni-axial tension testing. However, superplastic sheet is formed under mutiaxial loading condition in most forming practices. In the present study, superplastic characteristics of A15083 alloys were determined with using both a uni-axial and biaxial bulging tests. Specially, cone-type die was used to achieve constant strain rate under constant pressure condition. Even though constant strain rate under a certain pressure was achieved only approximately, a cone-type bulging test was found to be quite beneficial to get a multiaxial formability of superplastic materials.

The sheet parts are formed with dies conventionally. But this conventional forming process is not suited to small volume and varied production for the reason of high cost. For the solution of this problem, a new forming process, which is called CNC incremental sheet forming, is being introduced. This process can form sheet parts without die, and is very well suited to small volume and varied production in space flight and automobile. In this paper, dieless CNC forming system based on a machining center is developed. A special device to grasp and pull the blank sheet built in the machining center and tool path generation S/W from STL file of 3-D model are developed. Several sheet parts are incrementally formed to verify the effectiveness of the developed system.

Electroforming is a process that employs technology similar to that used for electroplating but which is used for manufacturing metallic articles, rather than as a means of producing surface coatings. Electroforming provides a cost-effective means of producing alloys and fully dense nanocrystalline metals as foils, sheets and complex shapes. It was able to make Fe-Ni foil with $5{\mu}m$ thickness by electroforming. Electroformed Fe-Ni alloy was nanocrystalline and the yield strength was in the range $2000{\sim}2800\;MPa$. The magnetic permeability at high frequency of electroformed Fe-Ni foil was higher than that of thicker foils.

Surface friction welding, SFW, is a newly developed solid state welding technology for joining of thin metal sheets. Workpieces are joined by frictional heat, shear deformation and plastic flow generated by friction between the rotating tool and surface of the workpiece. The SFW is an economical and environmentally conscious technology with high joining speed and excellent properties, and is expected to be used widely in various industries in the near future.

In this present study, an attempt was made to determine the deformation mode of the Zr-Ti-Cu-Ni-Be bulk metallic glass by compression test over a wide range of temperatures and strain rates. From the results, empirical deformation map could be constructed including the boundaries of different deformation modes. Considering power dissipation map and instability map developed on the basis of the Dynamic Materials Model (DMM), the processing map for extrusion could also be constructed. In addition, the macroscopic formability of this BMG alloy has also been examined through the extrusion in laboratory scale within undercooled liquid state. From the results of macroscopic extrusion formability, both deformation map and processing map present good criteria to determine optimal forming conditions.

Copper-based bulk amorphous alloy composite was synthesized by using the copper-coated $Cu_{54}Ni_{6}Zr_{22}Ti_{18}$ amorphous powder which was obtained by argon gas atomization. The amorphous powder having a super-cooled liquid region of 53 K was coated by crystalline copper by electroless coating. The consolidation was carried out by manufacturing performs and by the subsequent warm extrusion at 743 K. During the compression test at the room temperature, the composite containing a large fraction of crystalline copper displayed a larger plastic strain after yielding. FEM simulation revealed change in fracture modes in the composites depending on the amount of crystalline copper in the composites.

The deformation behavior of copper during equal channel angular pressing (ECAP) was calculated using a three-dimensional version of a constitutive model based on the dislocation density evolution. Finite element simulations of the variation of the dislocation density and the dislocation cell size with the number of ECAP passes are reported. The calculated stress, strain and cell size are compared with the experimental data for Cu deformed by ECAP in a modified Route C regime. The results of FEM analysis were found to be in good agreement with the experiments. After a rapid initial decrease down to about 200 nm in the first ECAP pass, the average cell size was found to change little with further passes. Similarly, the strength increased steeply after the first pass, but tended to saturate with further pressings. The FEM simulations also showed strain non-uniformities and the dependence of the resulting strength on the location within the workpiece.

적절한 가공조건을 통하여, 중 탄소강에서 SIDT를 적용하여 페라이트-시멘타이트 미세조직이 압연 직후에 얻어졌다. 또한 이와 같은 조건은 압하온도 $690^{\circ}C$, 높이 감소율 $70\%$ (변형량 1.2) 및 변형율 속도 1/s에서 가공하였을 때 얻어졌으며, 가공 직후 $730^{\circ}C$로 승온하여 약 30분간 유지 후 서냉한 조건에서 매우 연한 미세조직이 얻어짐을 알 수 있었다. 이는 기존 20 시간 이상의 구상화 열처리에 비해 매우 짧은 시간이며, 구상화 열처리를 통한 경험한 미세조직과 유사한 특성을 나타낼 것으로 예상된다.

In order to obtain the initial starting sample having a random texture and fine grains, aluminum alloy 3103 sheets were repeatedly deformed by CCSS up to six passages and subsequently annealed at $300^{\circ}C$ for 1h. These samples were cold rolled at room temperature and also warm rolled at $250^{\circ}C$. Changes in rolling temperature gave rise to the different texture evolution. Warm rolling led to the pronounced texture gradients comprising the shear texture at the surface and the rolling texture at the sheet center. The formation of the rolling texture components, i.e., the ${\beta}$-fiber, was promoted by cold rolling than warm rolling.

Dry sliding wear behavior of electro-pressure sintered Co, $Co-20\;wt.\%$ CuSn and $Co-20\;wt.\%$ WC composites were investigated. Wear tests of the materials were carried out using a pin-on-disk wear tester at various loads of 10N-100N under a constant sliding speed condition of 0.38m/s against glass ($83\%\;SiO_2$) beads. Sliding distances were varied with a range of $100m{\sim}600m$. A scanning electron microscopy was used to examine morphologies of worn surfaces, cross-sections, and wear debris. The $Co-20\;wt.\%$ WC composite had the highest and the $Co-20\;wt.\%$ CuSn composite showed the lowest wear resistance among the tested materials. All specimens exhibited low friction coefficients ranging from 0.12 to 0.4 at the applied load of 100N.

Alloy 718 is normally used for the stationary and rotating parts of gas turbines due to its excellent combination of high temperature mechanical properties, formability and weldability. The mechanical properties of the Alloy 718 depend very much on grain size, as well as the strengthening phases, ${\gamma}'\;and\;{\gamma}'$. Direct aging is normally used to enhance tensile strengths at high temperatures. The grain structure of the superalloy components is mainly controlled during thermo-mechanical process by the dynamic, meta-dynamic recrystallization and grain growth. In this study, the influence of grain structure and heat treatment on tensile properties of direct-aged Alloy 718 was evaluated.

The temperature difference between die and workpiece has been frequently caused to various surface defects. The distribution and change for the temperature of forged part should be analyzed to prevent the generation of various defects related with the temperature. The surface temperature changes were mainly affected by the interface heat transfer coefficient. Therefore, the coefficient is necessary to predict the temperature changes of die and workpiece. The temperature calculated by FEM result might be well compared with the measured temperature. However, it is impossible to measure directly the temperature distribution of forged part. Therefore, the comparisons between measured temperature and predicted values are preformed by the microstructure in various temperature. Since the differences of microstructure could be obvious, the temperature criteria is set near by the incipient melting temperature. The predicted temperatures are well coincided with the measured values.

The purpose of this study is to establish the optimal induction heating conditions of various preform types used for TR forging. The finite element model coupled electro-magnetic and transient heat transfer was employed to evaluate the distribution of temperature at the billet. Power control method was applied to control temperature of preform in induction heating because TR forging is not a continuous process. Power schedule that consists of heating and holding stage was suggested. In heating stage, power is inversely proportional to diameter of preform but the time of heating stage is directly proportional to the diameter of preform. But, in holding stage, the required power for thermal equilibrium per unit volume of the billet decreases with an increase in a diameter of billet due to the increase of efficiency.

As an automotive industry's demand for lighter materials gets bigger and bigger, a lot of new strength Al alloys have been developed recently. In the present study, Al 6xxx series alloys were designed to get the strength level of 350MPa with the elongation of $12\%$. For that purpose, three alloy systems were selected based on the thermodynamics calculation. The effect of both $Mg_{2}Si$ precipitate and excess Si amount on the newly designed alloys was investigated. Also, heat treatment procedure was studied to optimize the mechanical properties.

This research conducted milling tests to study effects of cutting environment conditions of ball end milts on the characteristics of high speed milling cutting process. KP4 steels and STD11 heat treated steels were used as the workpiece and WC-Co ball end mill tools with TiAIN coated were utilized in the cutting tests. Dry cutting without coolant and semidry cutting using botanical oil coolant by the MQL(Minimum Quantity Lubricant) device were conducted. Cutting forces, tool wear and surface roughness were measured in the cutting tests. Results showed that MQL spray cutting of KP4 and hardened STD11 specimens produced better surface quality and wear performance than dry cutting did.

This paper is studied on the effect of TiAlN coated Ball End Mill and MQL(Minimum Quantity Lubrication) cutting condition on cutting characteristic of high hardness steels. KP4 steels[HRC32] and STD11[HRC60] heat treated steels were used as the workpiece and WC-Co ball end mill and single and multi layer TiAlN coated ball end mill were utilized in the cutting tests. MQL device was used to spray botanical oil coolant. Result showed that TiAlN coated ball end mill were increased the cutting length than WC-Co ball end mill in the cutting speed[$245{\sim}320m/min$] about $2.3{\sim}5.7$ times for KP4 steels and about $2.5{\sim}4.3$ times far STD11 heat treated steels. The multi layer TiAlN coated ball end mill is good for KP4 steels than single layer coated.

Design modification of the stamping die for the upper member of a front end module carrier is carried out in order to improve the feeling qualify of the final product. The small inferiority induced by wrinkling near the wall of the FEM upper member has been inspected after the draw-forming process. The finite element simulation shows that the excess metal is developed by the irregular contact of the blank the tool and it remains after the final stroke. This paper proposes two guidelines for the modification: one is to add the draw-bead; and the other is to modify the tool shape such as the forming shape at the wall. Simulation results show that the proposed guidelines both guarantee the improved feeling quality.

In the present study, AZ31B sheets has a bad formability in room temperature, but the formability is improved significantly as increasing the temperature because of rolled magnesium alloy sheet has a hexagonal closed packed structure (HCP) and a plastic anisotropy. In this paper, after tensile test in various temperatures, strain rate, show the tensile mechanical properties, yield and ultimate strength, K-value, work hardening exponent(n), strain rate sensitivity(m). As temperature increased, yield, ultimate strength and K-value, work hardening exponent(n) are decreased but strain rate sensitivity(m) is increased. As cross-head-speed increased, yield, ultimate strength and K-value, work hardening exponent(n) are increased. And according to the temperature, how change the plastic anisotropy factor R. In addition, we observed how temperatures and cross-head-speed effect on microstructure.

Since Outerrace is one of the components of driving shaft for power train of automobile and transmits high torque, high strength and high toughness are necessary so forging process is adopted to manufacture such parts. Therefore, in order to improve strength and toughness, heat treatment is accomplished after plastic deformation(forging). Because Each component of driving shaft is mounted to automobile after a series of forging, machining and heat treatment, in order to evaluate mechanical properties of such components in use, plastic deformation and heat treatment must be considered. So, in this paper, tensile tests are performed with tensile specimens which have passed through a series of upsetting, machining and heat treatment to evaluate mechanical properties of such components.

In Micro injection process, it is needed to the technique of making micro die, Rapid Thermal Pressing (RTP) and other techniques. Those techniques are independent. But the mutual connected system of techniques is needed. The target of this paper is the design of micro mold and the development of the entire micro injection techniques for functional polymer.

In recent industry, according to pursuit the miniaturization and high-precision of machine part with development of new technology as IT and BT, the development of mold manufacturing technology for mass production is accompanied. This study proposes the design of micro mold-base, predicts the error of product through estimating transformation of injection process using FEM. Therefore the mold-base which is suitable for micro injection proposed in this study. Finally, the error of feature is analyzed by measuring the manufactured micro mold-base.

The factors affecting Ni-Co alloy electroforming were investigated to determine the optimum bath composition and electroplating parameters, like pH, temperature, and current density, suitable for high speed fabrication of a micro mold with longer lifetime. To obtain alloy deposits having uniform thickness and composition, electroplating parameters were finely tuned with home-made electroforming apparatus. Ni-Co alloy deposits had linearly increased Co with $Co^{2+}$ ion concentration in electroplating bath, and showing $412H_v$ of Victors hardness at $23wt\%$ of Co content. For Ni-Co alloy, sulfonate and diol related organic additives were very effective to alleviate its residual stress and surface roughness. The maximum deposition rate was $106{\mu}m/hr$ at 10ASD and the tensile strength of alloy deposit was 2 times larger than that of Ni only case.

Micro-lens patterned micro-mold fabrication method for Light Guiding Plate(LGP), kernel part of LCD-BLU(Back Light Unit), was presented. Instead of erosion dot pattern for LGP optical design, micro-lens pattern, fabricated by LIGA-reflow process, was applied. Optical pattern design method was also developed not only for negative pattern LGP, but also positive pattern LGP. During injection molding process, experimental study was conducted to improve replication quality and brightness of ${\sim}50um$ micro-lens pattern mold. The effect of mold temperature for the replication quality of micro-lens array was studied.

Since polymer materials at elevated temperatures are usually rate-sensitive, the analysis of RTP process requires considering the effect of the rate-dependent. The material behavior that exhibits rate-sensitivity is called visco-plastic. A two-dimensional visco-plastic finite element formulation which constitutive equation is based on the formulation proposed by Perzyna is presented. This Paper is purposed to calcuate pressure distribution on PMMA in compression process and to predict the relationship with defects after demolding process. This paper analyzes, both analytically and numerically, the pressure distributions on the surface of PMMA during open-die RTP process. In this research, PMMA is used to be simulated at $110^{\circ}C$ near the transition temperature.

Recently, injection molded plastic optical products are widely used, because injection molding process has advantages of low cost and high productivity. However, there remains residual birefringence and residual stresses originated from flow history and differential cooling. The present study focused on developing a technique measuring birefringence in optical plastic parts using R-G-B separation of white light. The main idea of an analysis comes from the fact that more information can be obtained from the distribution of retardation caused by different wavelengths. A complete system to give the quantitative values of retardation covering high order 2-D birefringence will be demonstrated. Further investigation is under way to improve the accuracy of the system using diodes as light sources.

RTP(Rapid Thermal Pressing) is to fabricate desired pattern on polymer substrate by pressing patterned mold against the substrate heated around glass transition temperature. For a successful RTP process, the whole process including heating, molding, cooling and demolding should be conducted 'rapidly' as possible. As the RTP process is effective in replicating patterns on flat large surface without causing shape distortion after cooling, it is being widely used for fabricating various micro/bio application components, especially with channel-type microstructures on surface. This investigation finally aims to develop a RTP process machine for mass-producing micro/bio application components. As a first step for that purpose, we intended to examine the technological difficulties for realizing mass production by RTP process. Therefore, in the current paper, 4 kinds of RTP machines were examined and then the RTP process was conducted experimentally for PMMA film by using one of the machines, HEX 03. The micro-patterned molds used for RTP experiment was fabricated from silicon wafer by semi-conduct process. The replicated micro patterns on PMMA films were examined using SEM and the causes of defect observed in the replicated patterns were discussed.

Friction welding was used to weld the turbine wheel and shaft and have a good welding quality. Friction welding was conducted an the two dissimilar material, Nimonic 80A and SNCrW. The control of friction welding process parameter such as flywheel energy, interface temperature, amount of upset have an effect on the mechanical properties of the welded joint. FE simulation can be a useful tool to optimize the weld geometry and process parameters. Flash shape and thickness weld is consistent with the simulated results. Process analysis was performed by the commercial code DEFORM 2D. Mechanical property of weld joints was evaluated by microstructure, chemical component, tensile, impact, hardness test so on.

The Hot Embossing Lithography(HEL) as a method for the fabrication of nanostructure with polymer is becoming increasingly important because of its simple process, low cost, high replication fidelity and relatively high throughput. In this study, we investigated the characteristics of hot embossing lithography as a nanoreplication technique. To grasp characteristics of nano patterning rheology by process parameters(embossing temperature, pressure and time), we have carried out various experiments by using the DVD(400nm pattern width) and Blu-ray nickel stamps(150nm pattern width). During the hot embossing process, we have observed the characteristics of the size effect. The quality of products made by hot embossing is affected by its cooling shrinkage. The demolding process at the glass transition temperature results in low quality because of the shrinkage of the polymer. Therefore, the quantification of the temperature condition is essential for the replication of high quality.

The housing of the fuel injector supports the rod, the niddle valve and the solenoid. Based on the procedure of process design, in this paper, the forming operation is designed by the rigid-plastic finite element method. The metal flow during the forming of the fuel injector housing is axisymmetric until the final forming process. The response surface method has been performed to reduce the under-fill and the maximum effective strain. From the results of RSM, the second order regression model of equation is calculated by the least square method and used to determine the optimal values of design variables by simultaneously considering the responses. It is noted that upper under-fill is affected by the design variables of the $2^{nd}$ forming process and lower under-fill is affected by the design variables of the 1st forming process.

The Advantages of hot machining are the reduction of cutting forces, tool wear, and the increase of material removal rates. In this study, a hot-machining characteristics of milling by CBN tip was exprimentely analyzed, and the influence of the surface temperature and the depth of cut on the tool life were investigated. The selection of a heating method for obtaining ideal temperature of metals in machining is important. Faulty heating methods could induce unwanted structural changes in the workpiece and increase the cost. This study uses gas flame heating. It is obtained that tungsten carbide-alloyed has a recrystallisation temperature range of $800-1000^{\circ}C$ which is the high heating temperature that might induce unwanted structural changes. If it is performed at temperatures higher than $800^{\circ}C$ in machining, the possibility of unwanted structural changes and the increased wear of tool can be shown. Consequently, in hot machining of tungsten carbide-alloy, this study has chosen $400^{\circ}C-600^{\circ}C$ because the heating temperature might be appropriate in view of the cost and workpiece considerations. The results of this study experimentally shows a new machining method for tungsten carbide-alloyed that decreases the wear rate of machining tools

Cross wedge rolling process is utilized to manufacture multi-stepped axis symmetrical parts. This process is generally performed under high temperature conditions in order to induce serious deformation. But cold cross wedge rolling process has been rarely studied due to the limits of deformation. Recently, the cold cross wedge rolling process has been utilized to enhance the material strength in specified parts of manufactured products. In this paper, experimental researches were carried out with various forming conditions of cold cross wedge rolling process in order to suggest the design guidance to make preform for cold cross wedge rolling. The tensile strength and the surface hardness of specified region were compared to that of initial material with the variation of the area reduction and the rotational speed of rolling die. With respect to the area reduction, the maximum tensile strength was linearly increased and the surface hardness was rapidly increased within lower percent of area reduction. The surface hardness was saturated over the rotational die speed of 0.8 RPM.

This paper deals with void crushing behavior by ingot forging process which consists of sequential operations of upset forging and bloom forging. The predicted results of void crushing behavior by the simplified global-local method using F.E. analysis showed that the inherent void at the top region of the ingots remains incompletely crushed even after several forging operations. From the results of the hot upset forging test using the billets with drilled voids, it was found that the bonding efficiency of the void after forging process increases with an increase in deformation, and a decrease of initial diameter of voids.

Cast-forging process has a lot of advantages in terms of saving materials along with enhancement of mechanical properties. Therefore, this process has been taken as one of candidate process to manufacturing automotive suspension parts. Since most of cast-forging parts are made with using Al-Si alloys of high castability, the mechanical properties largely depends on the primary ${\alpha}$ and eutectic Si particles. During hot forging step these microstructural features evolve with strain increment. In the present study, the mechanical property evolution was investigated in terms of microstructual evolution with strain. Specially, fracture behavior of A356 alloy was studied to find out how to improve the mechanical properties.

Steam Generator is one of the most important structural part of nuclear power plant. It is manufactured by various steel forgings such as shell, head, torus and tubesheet. These steel forgings have been made by open die forging process. After steel melting and ingot making, open die forging has been carried out to get a good quality which means high soundness and homogeniety of the steel forgings by using high capacity hydraulic press. This paper introduced the open die forging process and manufacturing experience of large tubesheet forgings which will be used for the steam generator of 1,400MW nuclear power plant.

The dimension of forged part is different with the die dimension by the various effects, such as, elastic deformation and thermal effect. And, the difference amounts are not same according to the forging conditions, for example, forging mode, flow stress, etc. Therefore, the use of FEA is effective to predict and update the required die dimension. However, the variables for FE simulation are also as many as variables in the experiment. The variables give very much effect to the accuracy of FE results. At first, the material model is very deeply affected to the estimated dimension of forged part. And the considering of loading and ejecting stages is also important to increase the dimensional accuracy. The experiment and FEA are performed to investigate the dimensional changes and accuracy in cold forging. Two types of upsetting are used to survey the effects of forging mode and stages.

A combination of deep drawing and cold forging process is tried to achieve near net shaping of automatic transmission part which has drum shape and thickness variation. It is key for successful shaping of the part to find out proper condition to combine two different forming methods. Finite element analysis can be utilized for that purpose effectively. Integrity, reliability, and durability of the part are improved by eliminating machining process. The developed process is applied in real manufacturing process successfully.

In the previous experimental study about extru-bending of angle product, the bending of extruded angle products with the '${\wedge}$' section and 'ㄱ' section can be abtained by the hot metal extru-bending machine with the two punches moving in the different velocity. The bending curvature can be controlled by the different velocity of billets through the two-hole container. This paper describes simulation of extru-bending process by the difference of punch velocities. The result of the forming simulation by $DEFORM^{TM}-3D$ shows that the bending phenomenon at the die exit during extrusion can be abtained by the two punches moving in the different velocity. And it is possible to design extrusion dies and to control the curvature of product through the simulation of extru-bending process by analysis