A simplified numerical procedure to predict drawbead restraining forces(DBRF) has been developed based on the hybrid membrane/bending method which superposes bending effects onto membrane solutions. As a semi-analytical method, the new approach is especially useful to analyze the effects of various constitutive parameters. The present model can accommodate general anisotropic yield functions along with non-linear isotropic-kinematic hardening under the plane strain condition. For the preliminary results, several sensitivity analyses for the process and material effects such as friction, drawbead depth, hardening behavior including the Bauschinger effect and yield surface shapes on the DBRF are carried out.

Experimental studies are carried out in order to investigate the effects of heat treatment on the surface machined by W-EDM. In this work, two ways of heat treatment after W-EDM are considered. As a comparison, the machined surface by a traditional method such as milling/grinding is also considered. Thereby, specimens are prepared by four different machining methods. Those are (1) milling and then grinding, (2) wire-cut electric discharge machining (W-EDM), and (3) low temperature heat treatment or (4) high temperature heat treatment after W-EDM. The resulting surface roughness are measured and the changes of surface microstructures are investigated using the scanning electron microscope (SEM) with energy dispersive X-ray spectrometer (EDS). In general, heat treatment after W-EDM result in smoother surface and better chemical composition at the machined surface. Especially, high temperature tempering could remove defects in the thermally affected zone, which cause an overall deterioration of the surface machined by W-EDM.

In this work, we have employed the strain gradient plasticity theory to investigate the effect of material size on the deformation behavior in metal forming process. Flow stress is expressed in terms of strain, strain gradient (spatial derivative of strain) and intrinsic material length. The least square method coupled with strain gradient plasticity was used to calculate the components of strain gradient at each element of material. For demonstrating the size effect, the proposed approach has been applied to plane compression process and micro rolling process. Results show when the characteristic length of the material comes to the intrinsic material length, the effect of strain gradient is noteworthy. For the microcompression, the additional work hardening at higher strain gradient regions results in uniform distribution of strain. In the case of micro-rolling, the strain gradient is remarkable at the exit section where the actual reduction of the rolling finishes and subsequently strong work hardening take places at the section. This results in a considerable increase in rolling force. Rolling force with the strain gradient plasticity considered in analysis increases by 20% compared to that with conventional plasticity theory.

In this study, effects of forming angle and friction coefficient on a initiation of the Mannesmann hole defect were analyzed by using a response surface method. The maximum effective plastic strain at center point of specimen is utilized for the prediction of the starting point of crack occurrence, which is suggested by the comparison of integrals of four different ductile fracture models between the histories of the effective plastic strain at center point. It was revealed that the principal stress at the center is the dominant element to the increase of the effective plastic strain. It was also verified by the simulation results from the comparison of experiment and simulation. It is provided that the forming angle of 25 degrees and the spreading angle of 1 degree can be a proper design condition without an occurrence of internal hole defect and an excessive slip.

Most of auto-body members are composed of stamping parts. These parts have the non-uniform thickness and plastic work hardening distribution during the forming process. This paper is concerned with the side impact analysis of the ULSAB-AVC model according to the US-SINCAP in order to compare the crashworthiness between the model with and without considering the forming effect. The forming effect is ca]ciliated by one-step forming analysis for several members. The crashworthiness is investigated by comparing the deformed shape of the cabin room the energy absorption characteristics and the intrusion velocity of a car. The result of the crash analysis demonstrates that the crash mode, the load-carrying capacity and energy absorption can be affected by the forming effect. It is noted that the design of an autobody should be carried out considering the forming effect for accurate assessment of crashworthiness.

Micro-alloyed steel or heat-treatment-free used in clean technology have been replacing for conventional quenched-and-tempered structural steels since the micro-alloyed forging steel was developed in early 1970s in Germany for saving money of heat treatment, simplified process, short delivery and good productivity. In this paper, ball stud assembled in steering system for automobile was selected to compare conventional process making heat treatment with new process using high strength micro-alloyed steel without heat treatment. The conventional process for ball stud was composed of a total of 6 steps including upsetting, forward extrusion, machining, burnishing and tread rolling with heat treatment and shot blasting. As opposed to conventional process, newly proposed process for ball stud using the clean technology without heat treatment is simplified such as forward extrusion, heading, upsetting, forming having a flange shape and tread rolling. Also net shape forming process to achieve specified process not to include machined step fur manufacturing the ball stud was applied to newly simplified process since micro-alloyed steel is difficult to be formed.

In order to numerically evaluate automotive hydro-formed DP-steel tubes on crash performance considering welding heat effects, the finite element simulations of crash behavior were performed for hydro-formed tubes with and without heat treatment effects. This work involves the mechanical characterization of the base material and the HAG-welded zone as well as finite element simulations of the crash test of hydro-formed tubes with welded brackets and hydro-forming of tubes. The welding heat effects on the crash performance are evaluated in efforts to improve the process optimization procedure of the engine cradle in the design stage. In particular, FEM simulations on indentations have been performed and experimentally verified for material properties of weld zone and heat affected zone.

Anisotropy has an important effect on the strain distribution in aluminum alloy sheet forming, and it is closely related to the thinning and formability of sheet metals. Thus, the anisotropy of the material should be properly considered for the realistic analyses of aluminum sheet forming processes. For this, anisotropy can be approached in two different scales: phenomenological and microstructural (polycrystal) models. Recent anisotropic models (Yld2000-2d; Barlat et al.[1] 2003, Cuitino et al.[2] 1992) were employed in this work. For the simulation using shell element, the method which can impose plane stress condition in the polycrystal model is developed. Lankford values and yield stress ratios are calculated along various directions. As planar anisotropic behavior, a circular cup deep drawing simulation was carried out to compare the phenomenological and microstructure models in terms of earing profile.

Effects of V on both the formation of Ti-Nb-V carbonitrides and mechanical properties of Ti-Nb bearing low carbon HSLA steels were investigated. Hot rolling process was simulated by using Gleeble 3500 system with the steels containing three different levels of V ($0{\sim}0.1wt.%$). Vanadium precipitated as Ti-Nb-V carbonitrides at austenite region but it did not precipitate as VC during austenite to acicular ferrite or bainitic ferrite phase transformation. As V content increased, the amount of Nb precipitates was decreased but the average size of Ti-Nb-V carbonitrides was increased due to larger diffusivity of V than that of Nb. Coarsened Ti-Nb-V carbonitrides could act as heterogeneous nucleation site during ${\gamma}{\rightarrow}{\alpha}$ phase transformation, thus, acicular ferrite transformation was promoted as V content increased, resulting in increase of upper shelf energy.

42Ni-Fe Invar alloy strips were fabricated using conventional ingot casting and melt drag casting followed by rolling. Mechanical properties such as tensile strength, elongation and blanking deformability of the strips were evaluated. The properties were strongly depended on fabrication methods. Tensile strength and elongation of all strips were in the range of $40-60kg/mm^{2}$ and 26-35%, respectively, which are enough values for the manufacture of the final products. In some of the strips, however, burrs occurred at deformed surface. The properties of strips were explained in terms of microstructure such as grain size and texture formation during rolling. Additionally, strips by melt drag casting method were compared to those by conventional ingot casting.

Torsion testing was employed to investigate the deformation and recrystallization behavior of coarse-grained Alloy 718, and the results are compared with the compression testing results. Mechanical testing was conducted on bulk Alloy718 samples within the temperature ranges, $1000^{\circ}C{\sim}1100^{\circ}C$. The strain gradient formed in the torsion specimens resulted in a recrystallization behavior which varied along the radial direction from the center to the surface. The flow curves based on effective stress and effective strain as obtained by Fields and Backofen's isotropic deformation theory and the dynamic recrystallization within the compression tested samples and torsion tested samples are different. The different deformation and recrystallization behavior can be rationalized by the fact that the deformation in the coarse-grained torsion specimens is not uniform and thus the strain gradient within the specimens cannot be analytically predicted by FE simulation. Thus, the extent of recrystallization cannot be properly predicted by the established recrystallization equations based on compression tests.

Bulk plastic forming characteristics were studied for the magnesium alloy, AZ31 in warm backward extrusion. Effects of process conditions such as extrusion ratio, forming temperature, and punching speed were investigated respectively. Variation of microstructure induced by the warm backward extrusion process was observed. Microstructure of the work piece showed evidences of recrystallization under the experiment conditions. It is estimated that in specific punch speed region fast stroke accelerates recrystllization and reduces the forming load.

The main purpose of the present study has been placed on investigating the mechanical properties and microstructures of C-Si-Mn-V steels for cold forming manufactured by controlled rolling and cooling technology. The steels were manufactured in electric arc furnace (EAF) and casted to $160{\times}160mm$ billet. The billets were reheated in walking beam furnace and rolled to coil, the stocks were rolled by Controlled Rolling and Cooling Technology (CRCT), so rolled at low temperature by water spraying applied in rolling stage and acceleratly cooled before coiling. Rolled coils were cold drawed to the degree of 16%, 27% of area reduction respectively without heat treatment. Microstructual observation, tensile test, compression test and charpy impact tests were conducted. The mechanical properties of the steels were changed by area reduction of cold drawing and it is founded that there are optimum level of cold drawing to minimize compression stress for these steels. From the result of this study, it is conformed that $80kg_{f}/mm^{2},\;90kg_{f}/mm^{2}$ grade high strength microalloyed steel for cold forming are developed by accelerated cooling and optimum cold drawing.

Micro-alloyed steels(MA steels) for cold forging was developed to replace the usual quenched and tempered steel. MA steels have several advantages over the conventional quenched and tempered carbon steels. First of all, energy consumption could be lowered due to the elimination of spherodizing annealing and quenching/tempering heat treatment. Also, bending during quenching could be avoided when MA steels are applied for manufacturing of long fastener parts. However, larger amount of load is exerted on the dies compared than in the case of conventional mild steels, which might lead to the earlier fracture of dies, when MA forging steels are applied in forging practice. Therefore, die lift could be a critical factor to determine whether HA forging steels could be widely applied in cold forging practice. In the present study, authors have investigated the forging characteristics of non-heat treated micro-alloyed steel by using a series of experimental and numerical analyses. Firstly, microstructural features and its effect on the deformation behavior have been studied. Numerical analysis has been done on the forging of guide rod pin to investigate for the optimization of forging process and die stress prediction.

The reduction behavior of $TiO_{2}$ in Al and Al/CaSi containing self-reducing $TiO_{2}$ briquettes(SRTB) was investigated. The maximum yield of Ti was expected with the slag composition of 45-55%CaO in the $CaO-Al_{2}O_{3}$ system. When $CaCO_{3}$ was used as a flux, the oxidation loss of reducing agent by $CO_{2}$ should be compensated, and therefore it leads to excessive requirement of the reducing agent. By using Al and CaSi mixture as a reducing agent of $TiO_{2}$, the reaction products both oxide and metal could be liquefied, and separated effectively with each other. As a result, the yield of Ti increases remarkably. The optimum mixing ratio of CaSi to Al is 78%CaSi-22%Al.

Recently, micro-alloyed steels which could eliminate heat treatments after forging has been developed. These non heat-treated micro-alloyed steels have several advantages over the conventional quenched and tempered steel for cold forging. First of all, long components can be fabricated with a better dimensional accuracy since bending of long forged part after quenching treatment could be avoided. And it is possible to eliminate two energy consuming heat treatment steps, which are a spherodizing before forging and quenching/tempering after forging. Therefore, more cost effective and environment friendly process could be designed. However, there is non-uniform distribution of strain occurred across the forged part, since these non heat-treated micro-alloyed steel use strain hardening mechanism. In the present study, it was investigated how to lessen non-uniformity and increase strength together for cold forging when a baking heat treatment is applied in micro-alloyed steels. For this purpose, micro-alloyed steels developed by Se-A Besteel recently was used for the experiment.

The gate mark in injection molded part is a kind of surface defects. The formation of gate mark has been investigated in this study. SEM photographs and surface roughness have been examined to study gate mark. The specimens were molded for various injection conditions, such as injection temperature, mold temperature, and injection speed. Gate diameter and mold surface condition were also molding variables. Gate marks were reduced as injection speed and mold temperature increased. Gate diameter and injection temperature did not affect the gate marks. No etching of mold surface showed no gate marks for any molding conditions.