Recently, the engraving of letters or a pattern on a product surface has received more attention especially in trying to satisfy the customer requirements. Half-piecing is a protrusion forming process that pierces only 40~50% of the material thickness. In the current study, the half-piercing technique for making clear letters by protruding sheet material was selected and studied. The influence of clearance and penetration depth was investigated by measuring the camber and extruded length of a protrusion after experiments. In addition, a numerical analysis was performed for the same working conditions and compared with experimental results. It is shown that, as the clearance increases, the camber of a protrusion increases rapidly and the extruded length decreases slightly. The deformation pattern around the cutting edge during half-piercing changes from an extrusion mode to a shearing mode as the clearance changes from minus to plus values. It is also confirmed that the experimental results show a good agreement with the numerical analyses.

The solenoid valve case of an 8-speed automatic transmission plays a role in maintaining the valve seal, which prevents an inflow of foreign substances into the transmission. The seal increases the reliability of the automatic transmission's performance. As a solution to pollution-related problems and to reduce fuel consumption, transmissions are being made with more gears to work more economically and have reduced fuel consumption. These newer transmission require greater dimensional tolerances and need to be manufactured with more precision. In the current study, the design of a multistage drawing considering both the product's height and limit draw ratio (LDR) of the material was performed using both a theoretical analysis and the expertise of industrial experts. The finite element modeling (FEM) simulation was performed using the commercial software, PAM-stamp, and tests of the dimensional measurements for a prototype were performed to verify the optimal progressive process.

In the current study, a new dynamic recrystallization model for predicting high temperature flow stress is developed based on a physical model and the mean field theory. In the model, the grain aggregate is assumed as a representative volume element to describe dynamic recrystallization. The flow stress and microstructure during dynamic recrystallization were calculated using three sub-models for work hardening, for nucleation and for growth. In the case of work hardening, a single parameter dislocation density model was used to calculate change of dislocation density and stress in the grains. For modeling nucleation, the nucleation criterion developed was based on the grain boundary bulge mechanism and a constant nucleation rate was assumed. Conventional rate theory was used for describing growth. The flow stress behavior of pure copper was investigated using the model and compared with experimental findings. Simulated results by cellular automata were used for validating the model.

Compression tests were conducted at the various temperatures and strain rates to investigate void formation and microstructures behavior of a 1.9wt%C ultrahigh carbon steel used in forged workrolls. The microstructure, grain size and volume fraction of cementite were determined using specimens deformed in the temperature range from 800 to $1150^{\circ}C$ and strain rates from 0.01 to 10/s. It was found from the microstructural analysis that the grain size is larger at higher temperatures and lower strain rate deformation conditions. In addition, a higher volume fraction of cementite was measured at lower temperatures. The brittle blocky cementite was fractured at $800^{\circ}C$ and $900^{\circ}C$ regardless of strain rate. As a result, numerous new micro voids were formed in the fragmented blocky cementite. It was also found that local melting can occur at temperatures of more than $1130^{\circ}C$. Therefore, the forging temperature should be controlled between $900^{\circ}C$ and $1120^{\circ}C$. The temperature rise, which depends on the anvil stroke and velocity, was estimated through cogging simulation to find the appropriate forging temperature and to prevent local melting due to plastic work.

In the previous work, a new forging process design, which included incremental upsetting, diffusion bonding and cogging, was suggested as a method to manufacture 1.9wt%C ultrahigh carbon workrolls. The previous study showed that incremental upsetting and diffusion bonding are effective in closing voids and healing of the closed void. In addition, compression tests of the 1.9wt%C ultrahigh carbon steel revealed that new microvoids form within the blocky cementite at temperatures of less than $900^{\circ}C$ and that local melting can occur at temperatures over $1120^{\circ}C$. Thus, the forging temperature should be controlled between 900 and $1120^{\circ}C$. Based on these results, incremental upsetting and diffusion bonding were used to check whether they are effective in closing and healing voids in a 1.9wt%C ultrahigh carbon steel. The incremental upsetting and diffusion bonding were performed using sub-sized specimens of 1.9wt%C ultrahigh carbon steel. The specimen was deformed only in the radial direction during the incremental upsetting until the reduction ratio reached about 45~50%. After deformation the specimens were kept at $1100^{\circ}C$ for the 1 hour in order to obtain a high bonding strength for the closed void. Finally, microstructural observations and tensile tests were conducted to investigate void closure behavior and bonding strength.

The aim of the current study was to predict shape recovery behavior of Ni-Ti shape memory alloy (SMA) wire after loading-unloading and after wire drawing. The superelasticity of SMA was analyzed by a hyper-elastic model for the Mullins effect using ABAQUS. Firstly, tensile tests and loading-unloading tests of the Ni-Ti SMA wire with a diameter 1.0 mm were performed using an MTS servo-hydraulic tester. The parameters for the Mullins effect were computed by ABAQUS based on curve-fitting of the loading-unloading test data. The proposed FE-model predicted the shape recovery of Ni-Ti SMA after wire drawing. Finally, the effectiveness of the model was verified by drawing experiments. The wire drawing experiments using the Ni-Ti SMA were conducted on a drawing machine(1ton, 50mm/s). In order to evaluate the shape recovery of Ni-Ti SMA, the drawn wires are annealed for 30min at $450^{\circ}C$.

This paper aims to evaluate quantitatively the springback characteristics that evolve in the sheet metal forming of an S-rail in order to understand the reasons of shape inaccuracy and to find a remedy. The geometrical springback is classified into six modes: angle change of punch and die shoulders, wall curl, ridge curl, section twist, and axial twist. The measuring method for each springback mode is suggested and quantitative measurements were made to determine the tendency towards shape accuracy. Forming experiments were conducted with four types of steel sheets that have different tensile strengths, which were 340MPa, 440MPa, 590MPa and 780MPa, in order to evaluate the effect of the tensile strength and the bead shape on the springback behavior. Springback tendencies show that they are greatly affected by the tensile strength of the sheet and the shape of the tools. Almost all springback modes except the section twist and the axial twist show a linearly increasing trend as the tensile strength of the sheet increases. The results can be used as basic data for design and for compensation of the press die geometry when forming high strength steels which exhibit large amounts of springback.

A numerical investigation of the butting process for an AZ31B magnesium alloy tube at elevated temperatures was conducted to develop a double-butted magnesium alloy tube. As a result of the current study, it was found that the amount of doming of the tube end, prior ironing-extrusion to obtain high wall thickness reduction are important factors for the butting process of magnesium alloy tubes. There is also a limitation of the thickness profile of butted tube due to buckling of tube wall during the stripping stage.