• Transactions of Materials Processing
• /
• v.18 no.5
• /
• pp.377-384
• /
• 2009

The shape of edge cracking in rolling process generally occurred "V" shape. This cracking is successively generated at width edge of strip. The edge cracking is developed to center of strip during rolling process. In the results, the strip is occurred fracture, and the productivity is gone down because of the extensive production time. Accordingly, we need to control crack propagation during rolling process. But, the control of cracking is very difficult in rolling process. Previously the studies of edge cracking were mainly performed on hot rolling process. In this paper, the shape of the edge cracking in rolling was estimated according to process conditions such as initial edge crack size, reduction ratio and tension using FE-simulation and the simplicity experiments on cold rolling process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.04a
• /
• pp.117-120
• /
• 2009

The rolling of flat slabs or sheet metal is probably the most advanced technique of metalworking technology. In spite of this very intensive activity, the problem if edge cracking has not been resolved. Although edge cracking is a major industrial problem, relatively little well-documented experimental work has been published on subject. Despite the paucity of exact experiments, it is reasonably certain from published data that three causes contribute to its occurrence; (1) limited ductility of the rolled material (2) uneven deformation at the edges and (3) variations in stresses along the width of the rolled material, particular near the edge. The present study was carried out to show the generation of edge cracking using ductile fracture criteria and FE-simulation. The validity of simulated results was verified by rolling experiments of steel strip.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.04a
• /
• pp.93-96
• /
• 2009

The high grade thick plate is in great demand in the ship building industry and the construction industry. The main problems to produce the high grade plate are residual stress and flatness of plate. In the previous research, Finite Element Analysis(FEA) was conducted for cold roller leveler to understand the behaviors of cold roller leveler under different conditions of thickness, intermesh, and yield stress. In this study, a numerical model of roller leveler is developed and the calculated results of this model are compared with the FEA results to show the validity of the numerical model. The optimal leveling conditions to improve flatness of plate are suggested using this numerical model.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.04a
• /
• pp.73-76
• /
• 2009

Increase in tensile strength of steel is important for fuel efficiency and $CO_2$ reduction. But the higher the strip strength, the more defect could be generated in hot strip mill. This study focuses on line-type edge scab. One of the causes for the defect is initial edge cracks commonly observed on a slab but their correlation has not been verified yet. Thus, the objective of this report is to verify if the edge crack is exactly the seed for edge scab. For this, we conducted pilot hot rolling test with cracked slab and compared the development of cracks and edge scabs on hot-rolled strip.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2005.10a
• /
• pp.406-409
• /
• 2005

In the forging operation of large ingot two break-down process are upsetting and cogging. The first purpose of upsetting is to ensure sufficient forging ratio for subsequent cogging operations and consolidate the voids along the centerline. The second purpose is related to improve the physical properties for a final product. Voids which are generated during the casting process can be one of the decisive defects of materials. So it is necessary to know the standard of Judgment for void-closure in upsetting operation. In practical conditions, FEM analysis(DEFORM 2D 8.1) was carried out to decide how much effective strain has influence on void-closure. It is finally suggested that the function consists of the effective strain of analysis data and the area rate of void.

• Transactions of Materials Processing
• /
• v.19 no.4
• /
• pp.248-252
• /
• 2010

In this paper, three-dimensional finite element analysis of thread rolling process of a 12 point flange head bolt is conducted using a rigid-plastic finite element method based metal forming simulator AFDEX 3D. A whole sequence of cold forming processes of a long shaft bolt composed of four forging stages and final thread rolling process is simulated to reveal the mechanism of thread formation. A mesh density control function is applied near the major plastic deformation region to achieve computational efficiency. It has been shown both numerically and experimentally that longitudinal lengthening or shortening is negligible in thread rolling.

• Transactions of Materials Processing
• /
• v.25 no.4
• /
• pp.242-247
• /
• 2016

CFD simulation with FlowVision^® is used to evaluate the capability of cooling channel in hot press forming dies. Two different types of cooling channels, dry drilled and pocket types are considered for comparison. Two different approaches for simulating cooling channel are considered. One is single-phase velocity calculation for coolant only and the other is multiphase thermal and velocity calculation for die, blank and coolant all together. Both approaches show better cooling performance in pocket type cooling channel. Also both approaches show their own effectiveness in designing cooling channel of hot press forming dies.

• Transactions of Materials Processing
• /
• v.17 no.8
• /
• pp.649-656
• /
• 2008

Springback is one of factors affecting precision in metal forming. Its effect is particularly prominent in bending process. In this study, bending and forging process are used in order to manufacture a micro spring with two bending region from $60{\mu}m$ diameter wire. Springback in the process lowers the precision of the micro spring. Overbending for springback compensation has wide usage in a general way. However, this method requires repeated modifications of press dies until the tolerance is allowable, which causes that production cost and time increase. In this paper, we analyzed the mechanism of springback in the forming process of the micro spring using finite element method. In addition, a simple method to control springback without modifying dies was proposed by performing numerical analysis with various parameters.

• Transactions of Materials Processing
• /
• v.5 no.1
• /
• pp.47-54
• /
• 1996

An improved nonparametric tool description based on successive refined nonparametric patches is proposed and the related criterion for refinement is also discussed. In the proposed scheme any required order of tool surface conformity can be achieved by employing successive refinements according to the suggested criterion. By using the suggested adaptive tool refinement technique based on the nonparametric patch tool description the locally refined nonparametric tool surface with economic memory size and sufficient accuracy as well as with favorable characteristics for contact treatment can be obtained directly from the parametric patch related with commercial CAD system. Computation is carried out for a chosen complex sheet forming example of an actual autobody panel in order to verify the validity and the efficiency of the developed tool surface description.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1994.10a
• /
• pp.118-132
• /
• 1994

This paper investigates a new method to design blocker geometry in rib-web type closed die forging. By examining various forging and blocker geometries, it was found that blocker geometry can be generated by eliminating high frequency mode from finisher geometry. In order to formalize the procedure, low pass filters, which can convert finisher to blocker geometry, are proposed. Also discrete Fourier transform is used for computational efficiency. The blocker geometry designed by the present method are compared with the one by an experienced designer. The blocker geometries are also validated by using FEM simulation. Present results shows that the frequency approach may offer a promising method to design blocker automatically.