Alloy 718 nozzle component was manufactured by hot working and electron beam welding process. In this process, domestic 718 materials were applied and evaluated. Hot compression tests were carried out at a lot of process conditions and microstructural evaluation was investigated. Using the results, FEM simulations were performed in order to optimize the hot working process. After hot working, forged work-pieces were machined and welded by electron beam. Final nozzle component were heat treated and their microstructure and mechanical properties were investigated.

According to industrial development, Ingots are more large and various. In particular large STS ingot. The probability of shrinkage cavity occurrence is higher than carbon steel and alloy steel. To manufacture ultra clean steel the technical development is nearly necessary for example controlling inclusions and total [H]. In this study, after measured the mold temperature and adjusted thermo conductivity of STS steel and compared existing mold to new one with CAE. As a result, the new mold more reduced than existing mold for the probability of shrinkage cavity occurrence.

In this study, evaluation system of the thermal properties of the exothermic agents was investigated. Exothermic agents property evaluation system was developed by metering variation of power supply. Thermal properties of exothermic agents was affected by material mixture condition of exothermic agents, however, it was not affected by temperature. It is possible to make various exothermic agents by means of regulating thermal properties which is based on property evaluation system of exothermic agents.

Inclusions in forged large steel ingots of plan carbon steel and tool steel are investigated using optical microscop observation and WDX analysis. The large nonmetallic inclusions which is over $30\sim300{\mu}m$ in their diameter were observed in the samples that has been no good on a nondestructive test. The most of the inclusions were consist of some kind of oxides, ${Al_2}{O_3}$, $SiO_2$, CaO, MgO in forms of particles and glassy with an iron particles. The experimental large steel ingot was cast with a pouring temperature which is about ten centigrade higher than the field standard. The inclusions were observed in the test ingot are the smaller than that was in a usual forged steel ingot and is spherical shape with a glassy agglomerated ${Al_2}{O_3}-SiO_2-CaO-MgO$ particle. The pouring temperature is affected on removing the nonmetallic inclusions during the solidification by a floating mechanism.

The studies for internal void closure have been conducted experimentally and numerically for open die forging. The FEM analysis is performed to investigate the deformation behavior of some internal voids in cast ingots during two upsetting stages. The calculated results of void closure behavior are compared with the measured results before and after upsetting. The shapes and sizes of each internal void are scanned by the X-ray scanner. From this result, the criteria for deformation amounts effect on the void closure can be investigated by the types of void. Closed voids could be compressed and eliminated after forging when the applied deformation amounts were larger than the critical effective strains. On the other hand, open voids could not be compressed and removed.

Impact behavior of large SF590A (Fe-0.65C-1.5Mn-0.035P-0.035S-0.3Cr-0.15Mo-0.4Ni-0.3Cu) forged propeller shaft was studied in this study. Charpy impact specimens were prepared from the forged product with different heat number. The impact value of each specimen with different heat number tends to vary greatly depending on the prior austenite grain size and, less significantly, on the amount of sulfur. The dominant metallurgical factors affecting impact behavior of SF590A forged product are discussed based on fractographic and metallographic observations.

This paper deals with the effect of radial parameters in cogging process such as reduction in height (Rh) and rotational angle ($\theta$) of a billet on a void closure for large forged products. Usually closing and consolidation of internal void defects in a ingot is a vital matter when utilized as large forged products, using a press with limited capacity and the sizes of the ingots becoming larger. Consequently, it is important to develop cogging process for improvement of internal soundness without a void defect and cost reduction by solid forging alone with limited press capacity. For experiments of cogging process, hydraulic press with a capacity of 800 ton was used together with a small manipulator which was made for rotation and overlapping of a billet. Size of a void was categorized into two types; $\emptyset$ 6.0 mm and $\emptyset$ 9.0 mm to investigate the change of closing and consolidation of void defects existed in the large ingot during the cogging process. Also open void and closed void in the ingot were tackled to show the differentiation of closing process of internal voids with respect to void sizes. In this paper systematic configuration for closing process of void defects were expressed based on this experiment results in the cogging process.

In order to resolve the problems which appear after the clean large ingot production process, the impurities which are involved in the steel smelting process should be removed by developing cleaner materials. Through the rationalization of cogging process that is the first forging process of large ingot the quality is to be improved. For the sake of the optimization of an open die forging process and the improvement of the subject matter frequency ratio, a hazard precise die forging process must be developed and a Near Net Shape Forming accomplished. As a result, energy can be reduced by minimizing an after control process. In order to produce large axes and other forming parts, processing techniques are to be developed. In this context, this paper is a study about a reduction ratio, dies width ratio and rotary angles, the amount of overlap, and intends to analysis cogging processes, utilizing Deform-3D cogging module

The predictive equation of void-closure was developed to evaluate void crush ratio with respect to the process variables in the cogging process of a large round bar. The comprehensive finite element analysis with the process variables such as reduction ratio and die width ratio was carried out. The predictive equation of void-closure for cogging process was established on the basis of the regression analysis with the extensive FE analysis results and verified by comparing the predicted results with FEA results with various forging passes.

We carry out three-dimensional simulation of pore closing processes during upsetting in open die forging. Several pores on a plane section of a cylindrical material are traced at the same time and the results of hydrostatic pressure and effective strain are discussed to reveal the parameters affecting pore closing phenomena. Five different sizes of pores are also investigated by simulation to reveal the pore size effect in pore closing during upsetting. AFDEX 3D is employed for this study.

Process simulation requires accurate and reliable data for a wide variety of material properties, ranging from thermal conductivity to flow stress curves. Traditionally such data are gathered from experimental sources, which has significant disadvantages in that not all of the required data is readily available, it may be from various sources that are themselves inconsistent, measurement of high temperature properties is expensive, and furthermore the properties can be sensitive to microstructure as well as to alloy composition. This article describes the development of a new multi-platform software program called JMatPro, which is based on CALPHAD methodology, for calculating the properties and behavior of multi-component alloys. A feature of the JMatPro is that the calculations are based on sound physical principles rather than purely statistical methods. Thus, many of the shortcomings of methods such as regression analysis can be overcome.

In this paper, several process parameter studies of the manufacturing process of the steel cords are carried out to verify the relation between the process parameters and the residual stresses on the steel cords. At first, the finite element analysis of the drawing process is performed and the residual stress distributions with respect to the wire material and the area reduction ratio are obtained. The residual stress of the drawn wire is imported the finite element analysis of the twisting process as an initial stress. After that a parameter study of the twisting process is carried out. The process parameters are the applied tension, the over-twisting angle and the tensile strength of the drawn wire. Based on these studies, the optimum values of the process parameters which can remove or reduce the undesired residual stresses are determined. The optimum value of the process parameters are confirmed by the finite element analysis of the elastic recovery process of the steel cords. Finally, the finite element analysis of the roller straightening process is done to study the variation of the distribution of the residual stress before and after the process.

Generally, there are several types in rear suspension. The rear suspension of subframe type consisting of side member and front/rear cross member is widely used in a medium car and full car. In the small car case, the beam of tubular type without independent suspension system is used to reduce manufacturing cost. The optimized rear suspension of subframe type using hydroforming method has been developed in this study. In designing suspension, the driving stability and durability performance should be considered as an important factor. The stability is related to dynamic frequency and durability is connected with stress analysis of structure. We focus on increasing the stiffness of suspension and decreasing the maximum stress relating to durability cycle life. For making use of the merits of hydroforming which is possible to make the bead, tube expansion, and feeding in desiring position, several optimization design techniques such as shape, size, and topology optimization are proposed. This optimization scheme based on the sensitivity can provide distinguished performance improvement in using hydroforming. Through commercial software based on the finite element, the superiority of this design method is demonstrated.

Hydroforming Technology has been applied to manufacture in various parts of automobile. Especially, Exhaust manifold has been applied to hydroforming method in the foreign advanced automotive company. Exhaust manifold runner is important exhaust parts that heat-resistant and exhaust flow characteristics are requested in the automobile. The purpose of this study is to optimize the manufacturing method of exhaust maniflold runner using FEA and to propose to get a optimization design direction. In addition, Comparative analysis between conventional exhaust maniflold and hydroformed exhaust maniflold has been done in view of weight-saving, manufacturing advantage.

Sled test id widely used to evaluate the performance of occupant's safety system in frontal crash environment without having to conduct a full-scale crash test. Steel bar breaking system is used to generate deceleration profile which is experienced by passengers in frontal crash. In this study, deformation analyses of steel bars were conducted using a commercial FE code. Several guidelines were proposed to improve the accuracy of simulation.

A new experimental model for determining drawbead forces, which modifies the dieface of Nine's experimental model, is introduced and the better validity of the drawbead opening and restraining forces of new model than those of Nine's is demonstrated. While Nine's model considers a blank holding force as one of forming variables, new model excludes it by removing blank holder in the dieface. The comparison of the strains found by FEM simulation of automotive fender draw forming process with those measured in a formed panel recommends the new model for accurate drawbead forces.

Large curved plate blocks are widely used to construct hull structure in shipbuilding industry. Most curved plates are manufactured by using manual method called as line heating that use deformation caused by residual stress after local heating along a line which is perpendicular to the curvature direction. However, its working environment is poor and its formability is totally dependent on an experienced technician. In view of that, multi-point dieless forming (MDF) technology that use reconfigurable punch arrays instead of one piece die is proposed in this study. The MDF process is based on a concept of equivalent die surface made by numbers of punches which has round tip at the end of it. In this study, numerical simulation for common curvature type such as saddle shape was carried out. In addition, experiments in the plate forming process were also conducted to compare with the numerical results in view of final configuration. Consequently, it was noted that the proposed dieless forming method has considerable feasibility to substitute the new process for conventional manual method.

We present an intelligent forging simulator AFDEX. The intelligent forging simulator is determined by the adaptive and optimal mesh generation technique and many intelligent application-oriented special functions which minimize the user-intervention during forging simulation. Of course, the solution accuracy should be optimized in the intelligent simulation. We have developed AFDEX to meet the requirement on intelligent simulation. Its characteristics are introduced with the help of typical application examples.

This paper is concerned with the analysis of elasto-plastic stress waves by a time discontinuous variational integrator based on Hamiltonian in order to more accurate results in one dimensional dynamic problem. The proposed algorithm adopts both time-discontinuous variational integrator and space-continuous Hamiltonian so as to capture discontinuities of stress waves. This study enables to preserve total mechanical energy such as internal energy, kinetic energy and dissipative energy due to plastic deformation for long integration time. Finite element analysis of elasto-plastic stress waves is carried out in order to demonstrate the accuracy of the proposed algorithm.

A unified hydrocode, ExLO, in which Largrangian, ALE and Eulerian solvers are incorporated into a single framework, has recently been developed in Korea. It is based on the three dimensional explicit finite element method and written in C++. ExLO is mainly designed for the calculation of structural responses to highly transient loading conditions, such as high-speed impacts, high-speed machining, high speed forming and explosions. In this paper the numerical schemes are described. Some improvements of the material interface and advection scheme are included. Details and issues of the momentum advection scheme are provided. In this paper the modeling capability of ExLO has been described for two extreme loading events; high-speed impacts and explosions. Numerical predictions are in good agreement with the existing experimental data. Specific applications of the code are discussed in a separate paper in this journal. Eventually ExLO will be providing an optimum simulation environment to engineering problems including the fluid-structure interaction problems, since it allows regions of a problem to be modeled with Lagrangian, ALE or Eulerian schemes in a single framework.

A brake system in automobile is one of the important parts that directly affect the safety of passengers. Particularly, disk brake module is applied to almost all kinds of automobile brake system due to its remarkable braking power and braking distance. In the disk brake module of an automobile, the bolt for tire wheel is assembled to the disk brake hub by interference fit (bolt pressing process). The process induces small deformation whose range is within tens of ${\mu}m$ and this deformation may cause the runout badness of the whole disk brake module, and even braking problems such as judder or squeal phenomena which makes the loss of braking efficiency. In this study, bolt pressing fit into hub was simulated by $ANSYS^{TM}$, a commercial structure analysis program. Also, the aspect and the cause of hub displacement were analyzed and the solution for decreasing runout of hub was proposed.

The press machine is actuated by the rotating motion of crank shaft and the reciprocating motion of slide. In recent years, unbalance moments and forces to the main frame attract many researches, as press technology becomes more miniaturized, precise, and rapid. In order to control vibrations caused by the rapid motions of the crank shaft and slide, this paper studies a resolution reducing the unbalance at the high speed knuckle press.

This paper presents a micro air pump actuated by PZT actuator (synthetic jet actuator) for air supply for micro fuel cells. The synthetic jet actuators are usually created by a traditional PZT-driven actuator, which consists of a small cylindrical cavity, in/outlet channel and PZT diaphragms. To design the micro air pump, a numerical analysis has been conducted for flow characteristics with respect to various geometries. A prototype of the micro air pump, with a size of $mm{\times}mm{\times}mm$, was fabricated by PDMS replication process and was conducted performance test. To control the PZT actuator, we used the SP4423 micro chips that can be amplified input voltage to reduce the controller size and the power consumption. With a voltage of 3V at 100Hz, the air pump's pumping pressure is 600pa and its power consumption is only 0.1mW.

We conduct finite element simulation of a cross-wedge rolling process using AFDEX 3D. The die is realistically modeled with emphasis on the hatched plicate over the slope or forming region. Coulomb frictional law is used to prevent slip between material and die. Constant shear frictional law is also investigated and it is esmphasized that the constant shear frictional law is improper for cross-wedge rolling simulation.

Micro forming is a suited technology to manufacture very small metallic parts(several $mm{\sim}{\mu}m$). In this study, the micro forming property was studied, using Al5083 superplastic alloy with micro grain, suitable for the micro forming process and Zr-BMG amorphous with pseudo-superplastic phenomena in the supercooled liquid state. Micro forming experiments under stastic load status showed that distortion by slip and spin of the grain system and slip inside the grain was observed in the Al5083 superplastic alloy. In case of Zr-BMG, because there is no grain, the distribution of the forming property was similar to the load distribution between punch and metal.

We apply a closed die forging technology to a large crankshaft of which forging weight amounts to 850kg. 40ton counter-blow hammer forging machine is used. The forging process is optimized to reduce the forming load using finite element simulation. AFDEX 3D is used for forging simulation. The experiment is compared with finite element prediction and a good agreement is observed. The successful development of a large crankshaft by the closed die forging technology will contribute to opening a new area of closed-die forging application and to enhancing competitiveness of national machinery industries especially including ship part and power generation industries.

LGP is a key component of LCD back light unit because it determines the brightness and sharpness of display image. Usually, it has optical patterns fabricated on the bottom surface. In the present paper the LiGA-reflow method was applied to fabricate the LGP mold. Furthermore, the optical simulation considering the replication ratio of pattern height was applied to the pattern design. The optical simulation through systematic correction scheme helped find the optimum distribution of pattern density. Finally, the stamper fabricated by this method was installed in the mold and LGP was produced by injection molding. As a result of luminance measurement for the final product, the average luminance and luminance uniformity was measured 3,180 nit and 84%, respectively. Consequently, the mold fabrication method using the LiGA-reflow and optical simulation(CAE) can save the expense and time compared with the existing fabrication methods(laser ablation and chemical etching).

Thermoplastic resin takes place stress relaxation and creep according to temperature and time. In room temperature, time dependent deformation (TDD) of polymer was carried out at previous study. In this study, it evaluates time dependent deformation to relate temperature. Nanoscale indents can be used as cells for molecular electronics and drug delivery, slots for integration into nanodevices, and defects for tailoring the structure and properties. Therefore, it is important to control pattern depth for change of indent depth by creep when using Nanoindenter. For evaluating TDD at high temperature, it is occurred thermal-nanoindentation test by changing hold time at maximum load. Temperature is putted at $90^{\circ}C$, hold time at maximum loads are putted at 1, 10, 50, 100, 200, 300 and 500s.

Recently, a demand of nano/micro patterned polymer for display or biochip has been rising. Then many studies have been carried out. Nano/micro-embossing is a deformation process where the workpiece materials is heated to permit easier material flow and then forced over a planar patterned tool. In this work, the hot-emboss process is performed with different forming conditions; forming temperature, load, press hold time, to get the proper condition for linear pattern fabrication on plated-type polymers (PC). Replicated pattern depth increases in proportion to the forming temperature, load and time. Reduction of the workpiece thickness increases according to press hold time. In process of time, reduction ratio of workpiece thickness decreases because of surface area increment of the workpiece and pressure decline on it.

Film insert melding is one of the surface processes that enhances functional or aesthetic qualities of an existing product's surface. In general, film insert molding consists of three processes including thermoforming, trimming and injection molding. Thermoforming, which is the first process of film insert molding, is the most important process because the variation of film thickness has an effect on the mold design and process conditions for the subsequent processes, that are, trimming and injection molding. This study is focused on predicting the film thickness distribution through film insert thermoforming process using commercial FEM code. In order to describe rheological behavior of thermoplastic film (ABS), G'Sell's viscoelastic constitutive law was adopted. The numerical model of film insert thermoforming was established, and the simulation to predict film thickness distribution was performed. Comparison between the results of simulation and experiment was made to validate the proposed finite element analysis.

AAO(Anodic Aluminum Oxidation) method has been known that it is practically useful for the fabrication of nano-structures and makes it possible to fabricate the highly ordered nano masters on large surface and even on the 2.5 or 3D surface at low cost comparing to the expensive e-beam lithography or the conventional silicon processing. In this study, by using the multi-step anodizing and etching processes, highly ordered nano patterned master with concave shapes was fabricated. By varying the processing parameters, such as initial matter and chemical conditions; electrical and thermal conditions; time scheduling; and so on, the size and the pitch of the nano pattern can be controlled. Consequently, various alumina/aluminum nano structures can be easily available in any size and shape by optimized anodic oxidation in various aqueous acids. In order to replicate nano patterned master, the resulting good filled uniform nano molded structure through electro-forming process shows the validity of the fabricated nano pattern masters.

Plastics is commonly used in consumer electronics because of it is high strength per unit mass and good productivity. But plastic parts are usually distorted after injection molding due to the residual stress after filling, packing, cooling process, and etc. And plastic material is to be deteriorated according to various temperature conditions and operating time, which can be characterized by stress relaxation and creep. The viscoelastic behaviour of plastic materials in time domain can be expressed by the Prony series of the commercial code, ABAQUS. In the paper, the process to predict the post deformation under cyclic thermal loadings was suggested. The process was applied to the real panel, and the deformation predicted by the analysis was compared with that of real test, which showed the possibility of applying the suggested process to predict the post deformation of plastic product under thermal loadings.

Injection molding operation consists of filling, packing, and cooling phase. The highest pressure is involved during the packing phase among the operation phases. Cavity pressure depends upon velocity to pressure switchover time and magnitude of packing pressure. The cavity pressure is directly related to stress concentration in the cavity of mold. Thus the observation and control of cavity pressure is very important to prevent mold cracking. In this study, cavity pressures were observed for operational conditions using the commercial CAE software, Moldflow. Operational conditions were velocity to pressure switchover time and packing pressure. Cavity pressures were also measured directly during injection molding. Simulation and experimental results showed good agreement.

High pressure is involved during injection molding operation specially packing phase. Cracks in the mold are often occurred by high cavity pressure. In this study, structural analysis of mold has been performed using commercial softwares, Abaqus and Ansys, to investigate cause of crack in the injection mold. Structural analysis contains four cases: stress distribution according to the cavity pressure, stress concentration according to the boundary conditions, stress concentration for inter-locking design of mold, and stress concentration for distributed cavity pressure. Through this study it was observed that the locations of stress concentrations were coincident with locations of crack. Robust mold design is being required to withstand high cavity pressure.

The cavity of mold is exposed to high pressure during injection molding operation. Injection molded articles with deep depth are often demanded as design variety increases. Mold becomes weak and deformation increases as the mold depth increases. Thus the injection molds for deep depth articles should be designed to hold out high pressure or stress and large deformation. Through this study, equation for mold design was examined and suggested novel method to determine equation for mold design with deep depth. Novel equation developed in this study was consisted with cantilever and two points bending while previous equation was modified from just cantilever bending. The validity of novel equation was verified through computer simulation.

In this paper, the magnetic domain states and recordability of the molded magnetic nanopillars were examined and analyzed by magnetic force microscopy (MFM) measurement. We focused on the some of the technical issues for MFM measurement regarding the lift height and geometry of the MFM tip. The effects of MFM tip shape and lift height on the MFM resolution were analyzed. Finally, we showed that the magnetic film on each molded nanopillars has a single magnetic domain state.

Currently, in automobile industry. the efforts to reduce the manufacturing cost by changing the process of manufacturing are continually performed. In this paper, we proposed a new manufacturing process, the roll bending of a ring plate of automotive fuel tank instead of conventional press blanking process to reduce material loss and manufacturing cost. Finite element analysis was used to optimize the roll bending process to assure rectangular cross-section of the ring plate. Also, spring-back analysis after the roll bending was performed and dimension of the bending die considering spring-back was analyzed. Finally, we verified a possibility for realization of the proposed method shape with prototypes.

The L-bending of inner-structure bonded sandwich sheet metal is examined by using a bending die attached to the material testing machine. The specimen is composed of top and bottom layers and a middle layer of pyramid-core structure and each layer is bonded by brazing. The variables chosen for experiments were clearance between punch and die, location of bend line on the specimen surface and clamping type of specimen during L-bending. Effects of these variables on deformation of specimen around die-corner radius were investigated. It was shown that the irregular shapes of recess are formed in the inner layer of bended parts and they greatly depend on working conditions.

In this study, a macroscopic approach was carried out to gain insight into the bending mechanism of metallic sandwich plates. Shear force-punch stroke curves for various clearances were analytically derived for mild steel (CSP 1N) sandwich plates with the total thickness of 3 mm and 0.5 mm face sheets. As the clearance increases, shear force of the inner structures and sensitivity of punch stroke decrease. These data are useful to derive a criterion of judgment for core shear failure and de-bonding failure during U-bending.

In recent years, developments of light weight vehicle are one of the most important issues in automotive industry. It is important to know the variations of the mechanical properties in the hydro forming process for the safe and durable design purposes. Generally, tube hydroforming process consists of three main processes such as bending, preforming, and hydroforming. It means that the strain hardening histories of final products are nonlinear. In this study, strain hardening behavior during hydroforming has been investigated by hydroforming of engine cradle as a model process. The variation of mechanical properties such as local hardness and strength were used as an index of strain hardening during respective processes. The correlationship between strength and hardness obtained from tensile test has been equivalently converted into correlation between hardness and measured strain.

Flow imbalance among the cavities was often observed in multi-cavity mold. The flow imbalance affects on the dimensions and physical properties of melded articles. First of all, the origin of flow imbalance is geometrical imbalance of delivery system. However, even the geometry of delivery system is balanced the cavity imbalance is being developed. This comes from the temperature distribution in the cross-section of runner, which is affected by the operational conditions. In this study, experimental study of flow imbalance has been conducted for various injection speeds. This study also suggests new runner design to eliminate flow imbalance in multi-cavity injection mold. Simulation and experimental results showed suggested new designed runner could eliminate or reduce flow imbalance in multi-cavity injection mold.

There are many different kinds of forming processes to make a tubular product such as hydroforming and tube drawing. However, we should consider a better forming process in view point of energy consumption and $CO_2$ emission to save our earth. In this paper we have conducted FEM simulations to the various forming processes for sheet and tubular products to compare their energy consumptions. One example is tubular product and the other for drawn cup. From the comparisons of total energy for hydrofroming and tube sinking processes, hydroforming is consumed more energy than tube drawing. Also the cup drawing from sheet metal and tube sinking for the cup with flange indicate that the tube sinking is better than cup drawing of sheet metal in energy consumption.

Magnesium alloy is expected to be widely used for mobile electronic appliances as well as automobile parts for its lightweight and EMI-shielding characteristics. In the present investigation, a Note-PC upper case made of magnesium alloy AZ31 sheet was developed by using the press forming technology at elevated temperature. Considering the press forming process and the formability of magnesium alloy sheet, the case shape and the press die was designed. The optimum forming condition was experimentally examined. Then the as-received magnesium alloy sheet was press-formed into the designed case shape under the optimum forming condition.

In order to study the effect of shot blasting condition on the formability of thin high strength steels, specimens were made by changing line speed of a commercial shot blasting plant with maintaining constant impeller condition. Surface roughness of prepared specimens was multiplied by lowering line speed or increasing density of shot impact. Formability was reduced as increasing shot impact. The elongation and stretching formability of shot blasted sheet were decreased by about 10% compared to original sheet. More significant decrease in bending formability was observed after shot blasting. This might be due to the concentrated impact near the surface where major strain occurs during bending process.

Most pedestrian-vehicle crashes involve frontal impacts, and the vehicle front structures are responsible for most pedestrian injuries. The vehicle bumper contacts the lower legs at first. The leading edge of the hood (bonnet) strikes the proximal upper leg and finally, the head and upper torso hit the top surface of the hood or windscreen. In essence, the pedestrian wraps around the front of the vehicle until pedestrian and vehicle are traveling at the same speed. Since the hood surface is made from sheet metal, it is a relatively compliant structure and does not pose a major risk for severe head trauma. However, serious head injury can occur when the head hits a region of the hood with stiff underlying structures such as engine components. The solution is to provide sufficient clearance between the hood and underlying structures for controlled deceleration of a pedestrian's head. However, considerations of aerodynamic design and styling can make it extremely difficult to alter a vehicle's front end geometry to provide more under-hood space. In this study, the safe hood will be developed by designing new conceptual inner panel in order to decrease the pedestrian's head injuries without changing hood outer geometry.

In this study, a design method of developed shape for double-curved pressure vessel segment heads was proposed in consideration of in-plane strain induced by forming works. In order to obtain the developed shape of double-curved plate, at first, the segments are subdivided into elements and then they are stacked into a series of strips producing the outline of the approximately developed shape. The developed shape was determined by imposing the in-plane displacement obtained from forming analysis and regression analysis on the outline of the approximately developed shape. The validation of the proposed design method was verified by applying it to the actual products.

Tool design is carried out for a press forming of a cross member in the rear suspension assembly based on the result of the finite element analysis. The analysis simulates the two-stage stamping process with the initial design and it fully reveals the unfavorable mechanism which develops inferiorities during forming. In this paper, a new design guideline is proposed to modify the process and tool shapes for a single-stage forming process. With the improved tool design, this study fabricates prototypes that satisfy the durability requirement.

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. In this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal SILL SIDE manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle. And also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

Incremental forming path to manufacture a thick concave steel plate using the line array roll set is designed. To find the optimum forming path, the forming processes are simulated by the finite element method. A general-purpose commercial software, MSC.MARC is used. The rolls are modeled as rigid surfaces and the thick plate is modeled as 8-node hexahedral elastic-plastic solid elements to predict accurate springback. It is found that the process can be successfully applied to the fabrication of the dual curvature ship hull plate

In this paper, tension tests and formability tests are performed to construct a database related to mechanical properties and the formability of the AZ31B Mg alloy sheet. A forming test with a hemi-spherical punch is conducted at varying temperatures to establish a forming limit diagram. In order to verify the applicability of the analysis using the conventional flow hardening model, a finite element analysis is performed on the hemi-spherical punch forming process and the results are compared with experimental ones. The study investigates problems involving a computational analysis that does not consider flow softening of the magnesium alloy at elevated temperatures.

It is known that the temperatures of die, punch, holder and punch pad need to be kept different to get better formability in Mg sheet forming processes. Heating and cooling channels are usually equipped in each tool to assign different temperature. This study focused on the optimal design of the heating and cooling channels for a cross-shaped deep drawing die set. While the die and blankholder were heated to and kept at $250^{\circ}C$ by using heat cartridges, the punch and punch pad were kept at much lower temperature than that of the die and blankholder by water circulating through cooling channels. All the approaches were done by numerical analyses, aiming to maximize the cup height and to minimize the punch corner radius without any failure.

Magnesium alloy sheets are usually formed at temperatures between $150^{\circ}C$and $300^{\circ}C$ because of their poor formability at room temperature. In the present study, the formability of AZ31B magnesium alloy sheets was investigated by the analytical and experimental approaches. First, tensile tests and the limit dome height test were carried out at elevated temperatures to get the mechanical properties and forming limit diagram, respectively. And then deep drawing of cross shaped die was tried to get the minimum corner radius and forming limit at specific temperature. Blank shape, punch velocity, minimum corner radius, fillet size, etc, were determined by finite element analysis physical try-outs. Especially, optimum punch and die temperature were suggested through the temperature-deformation analysis using Pam-stamp.

Since the sheet metal forming of Mg alloy is perform at elevated temperature, the effect of strain rates related with the forming temperature and forming speed and R-value is very important factor for formability and forming limits and deep drawing. It is investigated that the effect of material properties such as various temperature, forming speed and strain rates on formability and R-value of Mg alloy sheet in round cup deep drawing. Therefore, the investigation for process variables is necessary to improve formability and forming limits and deep drawing. Also, the effects of strain rate and drawbility were studied by the experiment. The temperature, forming speed, and strain rates and R-value are investigated. Forming of Mg alloy takes consider into temperature, proper forming speed and strain-rate and R-value the formed parts were good without defects for forming limits and deep drawing.

Magnesium alloy sheets have been extending their field of applications to automotive and electronic industries taking advantage of their excellent light weight property. In addition to their excellent light property, magnesium alloys have several other advantages: high specific strength, good welding capability and corrosion resistance. Taking advantage of these benefits, magnesium alloys have also been substituting the polymeric materials in the electronic devices industries. In sheet metal forming application with magnesium alloys, the lower formability and high springback due to the lower elastic property (Young's modulus=45 GPa) at room temperature are major hurdles by which magnesium alloys have limited applications. In this study, commercial notebook case was adopted as the benchmark model, and then design parameters and process conditions are analyzed by the finite element simulation and physical try-outs.

Electromagnetic forming (EMF) technology, which is one of the high speed forming methods, has been used for the forming process in various industry fields. Numerical approach by finite element simulation of the EMF process is presented in this study. The implicit code is used to obtain the numerical model of the time-varying currents that are discharged through the coil in order to obtain the transient magnetic forces. In addition, the body forces generated in the workpiece are used as the loading condition to analyze deformation of thin sheet metal workpiece using explicit code. Numerical approach for a dimpled shape by EMF process is carried out and the simulated results of the dimpled shape by EMF are reviewed in view of the deformed shape and formability evaluation.

Durability of product is an important technical parameter of a current interception device (CID) filter. This parameter is influenced by several factors, such as: environment condition, external force, shape of device, heat and so on. In this study, the effect of the geometry of the device on durability was carried out. The effect of shape on durability of device is presented by force-carrying capacity that a device can sustain a maximum external force. Studied parameters of the CID filter's geometry include clearance, thickness, and corner radius. Fracture criterion of Cockcroft and Latham was also used to predict the maximum force-carrying capacity of device.

A visco-plastic self-consistent (VPSC) polycrystal model has been applied to simulate texture simulation and anisotropic properties of DP steels during deep drawing process. In order to evaluate the strain path during deep drawing, a steady state was assumed in the flange part of deep drawn cup. The final stable orientations were strongly dependent on the initial location in the blank. The evolution of anisotropy of DP steel sheets has been demonstrated through comparison of plastic strain rate vector at the different plastic strain levels.

For the effective manufacture of doubly curved metal plates, a line array roll set (LARS) process is proposed. The suggested process utilizes a pair of upper and lower symmetric roll assemblies. In the process, the initial plate is progressed into the final shape in a stepwise or pathwise manner according to the basic principle of the incremental forming process. The deformation proceeds simultaneously in the longitudinal and transverse directions. Moreover, there is a close correlation between the deformation in the longitudinal direction and that in the transverse direction of the plates. Therefore, the finally formed shape in the incremental forming process is strongly dependent upon process conditions, such as the forming path and the forming increment. The manufacturing of arbitrary doubly curved plates with various curvatures is not an easy task because of such complicated behaviors of the plate; thus, the forming schedules for the desired shape should be carefully and accurately designed. In this study, several experiments with the LARS system were carried out for the fundamental investigation on process design for manufacturing of doubly curved plates.

In the present work, cross-roll rolling was carried out using a rolling mill in which the roll axis is tilted by $7.5^{\circ}$ towards the transverse direction of the rolled sample. The evolution of strain states during cross-roll rolling was investigated by three-dimensional finite element method (FEM) simulation. Parallel to cross-roll rolling, normal-rolling using a conventional rolling mill was also carried out in the same rolling condition for clarifying the effect of cross-roll rolling. It turned out that three shear rate components were all introduced to the rolled sample by the cross-roll rolling process, while only one shear rate component operated during normal-rolling.

The evolution of texture and microstructure during recrystallization was tracked after different cold rolling of aluminum sheets. Texture of the sheet center were differentiated by different strain states due to prior deformation. The evolution of recrystallization texture was studied with the amount of shear applied during cold rolling. The final grain size after recrystallization annealing was varied due to the effective strain during deformation.

In order to study the effect of lubrication during hot rolling, ferritic stainless steel (FSS) sheet were hot-rolled with and without application of lubrication. The effect of two hot rolling processes on the evolution of texture and microstructure after hot rolling, cold rolling and subsequent recrystallization annealing was studied by means of macro-texture analysis and microstructure observations. After hot rolling, the specimen rolled with lubrication showed rolling textures at the sheet surface, while the specimen rolled without lubrication displayed shear textures in the outer layers of the sheet. Hot rolling with lubrication was beneficial to the formation of strong recrystallization textures at sheet surface. However, hot rolling with lubrication led to the formation of orientation colonies in outer thickness layers of the recrystallized sheet.

We propose a criterion which predicts wrinkle initiation on workpiece in groove rolling process based on finite element analysis. Fundamental idea introduced in the criterion is to examine the difference between flat rolling which don't' cause wrinkling at all and groove rolling which usually accompanies it. The proposed criterion assumes that irregular distribution of shear strain on workpiece during groove rolling is attributable to the initiation of wrinkling. The proposed criterion has been applied to roughing train in the rod and bar mill of SEAH BESTEEL Inc. A new design for 2nd pass (square roll groove) was suggested, machined and applied. Results reveal that the proposed criterion in this study could point out the location of wrinkle initiation during groove rolling and could reduce onset of wrinkle on final products.

It is most important to design the roll pass in shape rolling process. However, roll pass design has been accomplished by experience and intuition of a skilled engineer up to now. And it has being produced throughout a lot of trial and error. Thus, in this study, we tried to analysis the rolling process of H-beam by using FEM program for the quantitative evaluation of the plastic deformation. It could be predicted that rolling load, torque, shape of cross section and distribution of effective strain each pass by the analysis of rolling from break down mill(2 Hi rolling) to finishing rolling(Universal rolling) considering the heat transfer.

Elasto-plastic finite element analysis was carried out for analyzing the severe plastic deformation behavior of copper specimens during groove pressing. Deformation localization was studied in terms of strain variations along the longitudinal direction. Plastic strain is lower at the local interface between the shear and the flat regions, which receive very little shear during the pressing cycle. Strain localization is more intensified with the number of rove pressing cycles, although the average strain level increases.

The influence of subsequent annealing treatment on the dynamic deformation and the fracture behavior of submicrocrystalline Al-4.4%Mg alloy is investigated in this study. After inducing an effective strain of 8 via equal-channel angular pressing at $200^{\circ}C$, most of the grains are considerably reduced to nearly equiaxed grains of $0.3{\mu}m$ in size. With an increment of various subsequent heat treatments for 1 hour, resultant microstructures are found to be fairly stable at temperatures up to $200^{\circ}C$, suggesting that static recovery will be dominantly operative, whereas grain growth is pronounced above $250^{\circ}C$. The results of tensile tests show that yield and ultimate tensile strength decrease, but elongation-to-failure and strain hardening rate increase with an increase in annealing temperatures. The dynamic deformation and the fracture behavior retrieved with a series of torsional tests are explored with respect to annealed microstructures. Such mechanical response is analyzed in relation to resultant microstructure and fracture mode.

Effects of microstructure on the toughness of low carbon HSLA steels were investigated. Nickel decreased the ferrite-austenite transformation temperature, resulted in increase of the fraction of bainitic ferrite. However, it was decreased with increasing deformation amount at austenite region. Since fine austenite grains formed by dynamic recrystallization under large strain transformed to acicular ferrite or granular bainite rather than bainitic ferrite. The effective grain size, thus, was decreased by deformation and it resulted in lower ductile-brittle transition temperature (DBTT). The bainitic ferrite was thought to inhibit the fracture crack initiation and to delay the crack propagation by its high dislocation density and hard interlath $2^{nd}$ phase constituents, respectively. Thus, DBTT was also decreased by Ni addition in low carbon HSLA steels.

High temperature deformation of Ti-6Al-4V alloy with a lamellar colony microstructure was investigated by hot compression and torsion tests. The torsion and compression tests were carried out under a wide range of temperatures and strain rates with true strain up to 2 and 0.7, respectively. The processing maps were generated on the basis of compression and torsion test data and using the principles of dynamic materials modeling (DMM). The shapes of the strain-stress curves in alpha-beta region and processing maps obtained on the two different tests have been compared with a view to evaluate the effect of the microstructure evolution on the flow softening behavior of Ti-6Al-4V alloy with a lamellar colony microstructure.

We investigate the mechanical behavior of a pre-heat treated steel of ESW95, which is being used for automotive parts including tie-rods to save manufacturing cost and enhance product quality. SCM435 is also investigated to reveal the characteristics of the pre-heat treated steel tested. AFDEX/MAT is used to extract the true stress-strain curve over the large strain with higher accuracy. It has been found that ESW95 has very week strain-hardening behavior which can be negligible compared with SCM435 and that the initial yield strength is quite high and the toughness of ESW95 reaches nearly 75% of SCM435. ESW95 is characterized by the weak strain-hardening behavior and high yield strength that can be lead to minimization of post-processing including heat treatment and straightening. ESW95 and SCM435 are also compared by applying them to ball-stud forging by computer simulation. It is expected that a great deal of change may take place in production as well as in service if the pre-heated steels are adopted.

A sandwich plate with a truss core is composed of two face sheets and a truss core between the face sheets. In this paper, a metallic sandwich plate with a pyramidal truss core is investigated numerically, for its deformation and energy absorption ability under dynamic loading. To find the effect of mechanical properties on crashworthiness in the sandwich plate with a pyramidal truss core, various pyramidal cores were simulated and investigated. It appears that relative density and shear modulus of a pyramidal truss core effect the change of energy absorption.

Light Mg alloy stands on the center of investigation due to the high potential of industrial application not only to the structural, but also to the functional fields. However, the intrinsic low strength and corrosion resistance have limited to extend its industrial use. In order to overcome the disadvantage, various attempts have been come to the modification of composition, resulting in finding Mg-Zn-Y alloys. The cast Mg-Zn-Y alloy leads to the high strength and hardness, low friction coefficient and low interfacial energy in both the ambient and elevated temperature.

During the drawing of reentrant section like a spline, the unfilled in the corner of dies or the bended product emerges from the large reduction of area, the complex shaped sections and other nonuniform properties in material and lubrication conditions. In this study, the drawing of the spline section with the non-rotary symmetry from a circular aluminum billet has been analyzed by using commercial code DEFORM-3D. A new die construction method preventing the spline from the drawback of bending and the unfilled defect has been suggested and verified through the analysis using centroid shift method and the hybrid construction between converged and diverged profile.

Effects of patenting temperature on bending fatigue resistance of pearlitic steel filaments were investigated experimentally. The fatigue resistance of steel filaments was carried out by using hunter machine, specially designed for ultra fine-sized steel wires, in the controlled conditions. The transmission electron microscopy (TEM) was used for observing the overall microstructure. It revealed that the fatigue resistance as well as tensile strength increased together with increase of patenting temperature from 510 to $600^{\circ}C$, while the endurance ratio ($\sigma_e/\sigma_{TS}$) of filaments decreased. It is believed that this variation of mechanical properties with change of patenting temperature should be strongly influenced by the change of microstructure. The bending fatigue properties of steel filaments were discussed based on microstructural parameters.

We carry out non-steady state finite element simulation of a porthole extrusion process for manufacturing a radiation pipe under isothermal assumption. It is assumed that welding takes place at the moment that the material contacts the plane of symmetry. Welding phenomena are revealed by observing the contacting mechanism of the material passed through the portholes. It is emphasized that mesh density control and intelligent remeshing during welding process govern the solution accuracy and the program applicability. AFDEX 3D is employed.

In this paper, ABAQUS, one of the implicit finite element codes, is used to analyze the U-channel Draw benchmark problem of NUMISHEET 2005. Forming and springback stages have been done consecutively to compare their results with the experimental ones. The main measures for comparing are the side wall curl and angle. The result by numerical analysis are shown generally to be correspondent with the experimental results that the max. error is confined under about 10%.

This research suggest one-body type scrapped styrofoam crusher with sprayed air (or water), which at present separately composed of dust eliminator, air supplier and crusher. Air (or water) that supplied from compressor injected to rotating twin roller through axis hole, and sprayed out of fine hole on the surface. The crusher that manufactured with sprayed air (or water) can make high-quality primary styrofoam removed pollution and dust. In case of mixed sprayed air and water, clean degree of crushed styrofoam was higher than single sprayed air. This could be contributed to reduce environmental pollution, cost and space in standpoint of recycling scrapped styrofoam.

In this paper, we designed the main mechanism of high throughput device for rod-cuts of spent fuel. For this, we analyzed the mechanical methods(slitting, ball mill, roller straightening) and chemical methods(muffle furnace, rotary kiln). As the results, methods of ball drop and rotary drum for concepts design were selected in the analysis step. For enhancement of oxidation rate, we devised the blades on the reactor with mesh type. Also, for enhancement of decladding rate, we designed ball size and rotation reactor with mesh type and devised the vacuum system for fission products. Mechanisms of oxidation and recovery can simultaneously handle the rod-cuts of spent fuel and independently recover. The results of mechanism design can be used for scale-up of high throughput device.

Drawability and other mechanical properties of sheet metals are strongly dependent on their crystallographic orientations. In this paper the formability of the AA 5052 Al alloy sheets was investigated after asymmetric rolling and subsequent heat treatment. In most cases, after asymmetric rolling specimens showed a fine grain size and subsequent heat treated specimens showed that the ND//<111> texture component were observed. The anisotropy of formability is often described by the plastic strain ratios (r-value) as a function of the angle to the rolling direction in sheet metal. For a good formability, a high r-value is required in sheet metals. In the asymmetry rolled and subsequent heat treated Al alloy sheet, the variation of the plastic strain ratios have been investigated in this study. The plastic strain ratios of the asymmetry rolled and subsequent heat treated AA 5052 Al alloy sheets were higher than those of the original Al sheets. These could be related to the formation of ND//<111> texture components through asymmetric rolling in Al sheet.

The aim of this work is to compare the microstructure, the texture, of an AZ31 Mg alloy processed via cold rolling process. Initial AZ31 Mg alloy sheet samples with strong {0002} texture were cut along the angles of 12.5 and 25 degrees to normal direction (ND). These specimens were rolled in room temperature condition. The microstructure was characterized by optical microscopy and the texture was measured by X-ray diffraction.

Anodic aluminum oxide (AAO) which prepared with two-step anodizing method (with dissimilar solutions) was used as a template to fabricate highly ordered, free standing metal nano-rods. AAO nano-template technique can realize self-organized hexagonal pore structure with nanometer dimension size, it's easy to control pore diameter, length and density by varying anodizing conditions. Ni and Ni/Fe/Cu multi-metal layer nanorods were electrochemically deposited into AAO nano-template by AC voltage in simple sulfate solutions.. The properties of samples are tested by X-ray diffraction (XRD), field emission microscopy (FE-SEM).

Aluminum brazing needs normally careful control of temperatures due to little difference between brazing temperatures and melting temperatures of base materials. Unsuitable processing conditions such as brazing temperature, gap between brazed materials, inadequate feeding of flux, etc. can lead to occur joining defects. In this study, A357 was used as a filler metal for the brazing of pure aluminum base materials. A357 was brazed at temperatures in the semi-solid state. Interface microstructures with base materials were observed using OM and SEM/EDS and compared to conventional aluminum brazing.

This study aims to design the high-capacity vol-oxidizer using simulated fuels instead of spent nuclear fuels. Simulated fuels are fabricated by blending tungsten powder with silicon carbide powder, and thereafter, paraffin coating covers simulated fuels to increase their strength. An oxidation experiment using simulated fuels have been carried out in order to analyze oxidation characteristics similar to spent fuels. After oxidation, simulated fuels were almost oxidized to be powders. Increased volume of simulated fuels approached to spent fuels. These results can be utilized as important informations for designing a high-capacity vol-oxidizer.

The effect of B on the hot ductility of Fe-29Ni-17Co Kovar alloy and the mechanism of high temperature deformation behavior were investigated. Hot-tensile test was carried out at the temperature range of $900^{\circ}C-1200^{\circ}C$. Optical microscopy and scanning electron microscopy were used to investigate the microstructure and fracture during hot deformation. The hot ductility of Kovar alloy was drastically increased with the addition of Boron. The improvement of hot ductility results from the grain boundary migration mainly due to the dynamic recrystallization at lower temperature range($900^{\circ}C$).

The residual stress generated in the boron steel blank formed via hot press forming process was predicted by JMatPro, a material property modeler, and Abaqus. The numerical predictions were compared by the experimental measurements obtained by the instrumented indentation. Both the predicted and measured principal stresses monitored at the outer surface of central bending position were qualitatively in good agreement. It was concluded that the residual stresses generated from hot forming process is not negligible as it has been generally assumed, although the spring back deformation is quite small. This should be specially considered from the part design stage since the tensile nature of the residual stress exhibited on the surface may lead to the stress corrosion cracking.

In generally, a high pressure fuel injection pipe has been often used as a fuel supply line in automobiles or other diesel engines. Such conventional high pressure fuel injection pipe, however, has suffered from the problem that is folding and hair cracks created therein. The defects can be locally formed in the inner wall surface of the pipe at the connecting head leading to a flow path when the pipe is deformed by the heading process. In the study, in order to prevent the folding in the inner wall surface of the pipe during the heading process, FE-analysis has been used in the die design.

본 연구에서는 하이드로포밍 공정을 적용한 엔진크레들 제품에 대해 최종 제품의 강도를 평가하고자 하였다. 먼저 적용 판재인 370과 440 소재에 대해 인장시험을 수행하여 소재의 경도와 강도의 상관관계를 분석하여 경도와 강도의 변환식을 도출하였다. 그런 다음 예비굽힘, 예비성형, 최종성형된 제품의 각 공정에 따른 유효변형률을 측정하고 같은 위치에서의 경도를 측정하였다. 측정된 경도는 앞서 도출한 경도와 강도의 변환식에 대입하여 각 공정을 마친 제품의 강도를 예측하고 결국 하이드로포밍된 엔진 크레들 제품의 유효변형률에 따른 강도를 예측식을 실험으로 도출하였다. 그 결과 예비굽힘, 예비성형, 최종성형을 마친 엔진 크레들 제품에 대해 유효변형률이 $24{\sim}72%$로 변하였고 이때 HF370의 경우에는 유동응력값이 $375{\sim}500MPa$로 증가하여 원소재에 비해 성형 후 $25{\sim}66%$의 강도증가량을 보였고, HF440의 경우에는 $470{\sim}565MPa$로 증가하여, 원소재에 비해 $17{\sim}41%$로 강도가 증가하는 것으로 나타났다. 그리고 이와 같은 변화값을 이용하여 유효변형률과 강도의 상관관계를 도출하였다.

LTCC (Low Temperature Co-fired Ceramic) has been successfully applied to ceramic substrates for circuits and micro-fluidic systems and has proven its superior performance in a variety of applications. The prediction of shrinkage in LTCC process is an important for dimensional control of micro LTCC products which has influences on electronic characteristics. For avoiding the unpredictable shrinkage of LTCC during the sintering which makes accurate placement of the circuit devices difficult, pre-processes such as WIP (Warm Isostatic Pressing) and lamination must be modified. The objective of the present investigation is to establish a proper WIP conditions for near net shape fabrication of LTCC products. This paper discusses the influence of WIP conditions on the dimensional change of LTCC sheet. In the investigation, it is shown that the shrinkage values of sheets depend on WIP conditions and sheet directions. This work is a quantitative evaluation of the effect of WIP pressure on shrinkage of LTCC sheet. Additionally, the results show anisotropic shrinkage behaviour of sheet during LTCC process.

We have replicated nanopillar arrays using injection molding process of active heating and cooling method by several peltier devices. The injection melding has a high accuracy ed good reproducibility that are essential for mass production at low cost. Conventional molding processes widely use the water-based mold heating and air cooling methods. However, in case of replication for nano-patterned structures, it caused several defects such as air-flow mark, non-fill, sticking and tearing. In this study, periodic nano-scale patterns are replicated by using injection molding with Peltier devices. Porous nano-scale patterns, which have pore diameter range from 120nm to 150nm, were fabricated by using anodizing process. Periodic nano-pore structures ( $20mm\;{\times}\;20mm$) were used as a mold stamp of injection molding. Finally, PMMA with nanopillar arrays was obtained by injection molding process. By using the Peltier devices, the temperature of locally adiabatic molds can be dramatically controlled and the quality of the molded patterns can be slightly improved.

Recently, use of adhesive bonding technology is increased to achieve the multi-material design for lightweight structure in automobile industry. In this paper, the fracture strength of adhesive has been studied with the single lap shear test conducted at different temperatures. The joint specimens are made from Al 5052 and SPRC 440 bonded with structural epoxy adhesive. The operating temperature has been considered up to $150[^{\circ}C]$ and the single lap shear test has been conducted with 5mm/min tensile rate. Fracture strength of adhesive bonded joint has been decreased with increase of operating temperature. The fracture strength at the $100[^{\circ}C]$ was shown about half of that at room temperature.

Effect of prior deformation on the sliding wear of the ultra-fine grained (UFG) ferrite-martensite dual phase (DP) steel was investigated. The UFG DP steel was fabricated by the ECAP and subsequent intercritical annealing. The steel was cold rolled before the wear test, and the effect of the prior deformation on the wear was examined. The wear tests were carried out at various loads against a bearing steel ball. The wear rate of the UFG DP steel that did not experience the prior deformation was higher than that of the coarse-grained (CG) DP steel, because of more severe surface shear deformation. The wear rate of the specimens with prior deformation was much higher than that of the specimen without prior deformation. The deformed CG DP specimen showed higher rate than the deformed UFG DP specimen, and the rate-variation of the CG DP steel was much bigger under the same test condition.

N-Type $SbI_3$-doped $95%{Bi_2}{Te_3}-5%{Bi_2}{Se_3}$ compounds were prepared by a gas atomization and Magnetic Pulsed Compaction process. The dynamic recrystallization and thermoelectric properties of the MPCed bulks with consolidation temperatures and times were investigated by a combination of microscopy, XRD and thermoelectric property testing. The microstructure of MPCed bulk shows homogeneous and fine distribution through consolidated bulks due to dynamic recrystallization during hot MPC. This research presented the challenges toward the successful consolidation of thermoelectric powder using magnetic pulsed compaction (MPC).

The effect of consolidation temperature on the microstructure, density and mechanical properties (especially, wear property) of $Al_{92.5}-Fe_{2.5}-Cr_{2.5}-Ti_{2.5}$ alloy fabricated by gas atomization and magnetic pulsed compaction was investigated. All consolidated alloys consisted of homogeneously distributed fine-grained fcc-Al matrix and intermetallic compounds. Relative higher mechanical properties in the MPCed specimen were attributed to the retention of the nanostructure in consolidated bulk without cracks. The as consolidated bulk by magnetic pulsed compaction showed the enhanced wear properties than that of a general consolidation process. In addition, the wear mechanism and fracture mode of MPCed bulk was discussed.

A new forming process of the large-size forging within the limit of forming loads is developed by introducing the drawing process, which usually used to apply to sheet forming. For the development of the forming process, corresponding numerical simulation are carried out. The approach is based on the Taguchi method, and utilize the DOE for design of FEM analyses. In this study, the important factors are chosen at first, and then the concept of signal-to-nose(S/N) rate is applied to evaluate the formability of large size forging-products, and each value of the design parameter is determined.

Insert-injection molding can inject two different materials or two colors in the same mold and process. If this injection process use, product has ability because the base part maintain strength and specified part can inject soft-material. It makes the cost down by single operation automatically for saving wages. In this paper, we designed double-injection mold for automobile remote control to inject secondary using this part as insert after inject external appearance of product. CAE analysis was progressed gate location and runner size as variable and analysis result is reflected in mold design process. As a result, it could solved badness that is generated at the conventional mold. Additionally, cost is downed by reducing loss of runner as well as could omit painting process because surface of finished product is improved through new mold.

Recently, GMP(Glass Molding Press) process is mainly used to produce aspheric glass lenses. Because glass lens is heated at high temperature above Ty (yielding point) for forming glass, the quality of aspheric glass lens is deteriorated by residual stresses which are generated in a aspheric glass lens after forming. Before this study, as a fundamental study to develop forming conditions for progressive GMP process, compression, strain relaxation and thermal conductivity tests were carried out to obtain the visco-rigid plastic, the visco-elastic and thermal properties of K-PBK40 which is newly developed and applied for precision molding glass material, In this study, using the experimental results we obtained, a glass lens forming simulation in progressive GMP process was carried out and we could forecast the shape of deformed glass lenses and residual stresses contribution in the structure of deformed glass lenses after forming.

In the present study, the effect of cold reduction ratio on the spherodization rate of SK85 high carbon steel sheet was investigated. High carbon steel sheet fabricated by POSCO was soaked at $800^{\circ}C$ for 2 hr in a box furnace and then treated at $570^{\circ}C$ for 5 min in a salt bath furnace followed by water quenching to obtain a fine pearlite structure. Cold rolling was conducted on the sheets of fine pearlite by reduction ratios of 20, 30, and 40 % and heat treatment for spheroidization was carried out at $720^{\circ}C$ for the various time intervals from 0.1 to 32 hrs. Area fraction of spheroidized cementite was measured with an image analyzer as a function of cold reduction ratios and duration times.

Precipitation characteristics of the Fe-36Ni based high strength Invar alloy for power transmission wire was investigated in this study. High strength can be obtained in this alloy through precipitation hardening and strain hardening by cold working. $FactSage{(R)}$ in this study, revealing that equilibrium phases which can be formed are two kind of MC-type precipitates and MoC carbide. The latter stoichiometric carbide was expected to be formed at relatively lower temperature $770^{\circ}C$. High strength above 1000MPa and 40% of elongation were obtained at room temperature in both cases.

In the recent year, Unmanned helicopters of airline industries are using in various industries such as monitoring system, agriculture and forest fire. A unmanned helicopter is needed a powerful engine for transport weighty payload and have to need a light weight. Therefore it is necessary a light weight transmission of the unmanned helicopter. Initially a rectangular transmission housing has been considered, but an empty space in the housing is not useful for light weight design. In this study, new model has been introduced into the transmission housing by using rapid prototyping. As a result, the weight of new transmission housing can be reduced very much as 67%.

In this study, the failure in circular cup deep drawing simulation at warm temperature is predicted using forming limit diagram (FLD). The FLD is used in sheet metal forming analysis to determine the criterion for fracture prediction. The simulation with heat transfer of circular cup deep drawing at warm temperature was conducted. To predict the failure, the simulation with heat transfer used FLD at temperature in the vicinity of maximum thinning. The result of the simulation with heat transfer shows that the drawn depth increases with increasing temperature and is in accord with the experimental results above $150^{\circ}C$. The FLD provides a good guide for the failure prediction of warm forming simulation with heat transfer.

A condensed model is proposed for the simulation of forming of sandwich sheet with pyramid core. A corresponding finite element analysis for L-type bending is carried out to prove the accuracy and the effectiveness. Simulation results are compared with those of experiment. Deformation shape and post-buckling behavior by simulation are in good agreement with those of experiment for the considerable range of deformation. From the comparison of force-displacement curve, it is shown that the proposed model shows good prediction of the forming force compared to the experiment. Thus, the effectiveness of the proposed method is sufficiently demonstrated.