• Composites Research
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• 제16권1호
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• pp.1-12
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• 2003

본 연구는 보강재의 부피분율이 49%, 56%, 63%첨가된 패키징용 SiC/Al복합재료를 가압주조법을 통해 개발하였다. SiC/Al복합재료는 0.8%의 무기성형제와 $Al_2$O$_3$섬유가 SiC입자에 비해 부피비 1:10의 비율로 첨가되었으며 새로이 고안된 몰드에서 제조되었다. 제조된 SiC/Al복합재료에 대해 30-300 구간에서 열팽창 계수를 측정하고, FEM수치해석과 비교하여 온도에 따른 특성을 분석하였다. 실험결과 SiC/Al복한재료의 열팽창계수는 혼합법칙, Turner모델의 중간값을 가졌으며 상온에서는 Turner모델에 가깝다가 온도가 높아질수록 혼합법칙에 가까와졌다. 이러한 특성은 모재의 소성변형 및 잔류응력에 의한 것으로 본 연구에서 제안한 모재와 보강재 사이에 작용하는 평균응력 차이로부터 분석이 된다. 해석결파 모재의 소성변형이 시작되는 온도에서 SiC/Al복합재료의 열팽창계수가 급격히 증가하였으며, 가공 잔류응력은 이러한 소성변형의 시작온도를 고온으로 이동시킴으로써 열팽창계수에 영향을 끼침을 밝혔다. 이러한 일련의 연구를 통해 온도에 따른 열팽창 특성은 복수입자모델에 의한 2차인 해석을 통해 성공적으로 분석됨을 보였다.

• 대한조선학회논문집
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• 제39권1호
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• pp.82-89
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• 2002

선상가열에 의한 판 변형 예측은 고유변형도법에 의해 효율적으로 예측할 수 있다. 종래의 용접에서의 고유변형도 결정 방법은 용접 실험을 통하여 온도분포와 강의 상변태 영역(Ac3)을 시편을 절단하여 계측하고 이를 고유변형도 영역으로 간주하는 것이었다. 선상가열의 현상은 용접과 유사하므로, 용접과 같은 조건 하에서 얻어진 결과를 그대로 선상가열 해석에 이용하여 왔으나 이 결과는 가열 패턴이나 판 두께에 제한을 가지고 있다. 또한 현장에서는 선상가열 후 수냉 처리하는데 그 과정에서 강이 원래의 상으로 돌아가지 않고 마르텐사이트가 되면서 전단 소성 변화를 일으킨다는 점에 착안하여, 본 연구에서는 종래에 시편의 온도계측과 상변태 영역을 직접 계측하는 파괴검사법을 FEM을 이용한 이론해석으로 대체하였다. 즉 임의의 적절한 열속 모델에 대한 온도 분포를 얻고, 조직변화에 따라 추가적으로 발생하는 소성 영역을 고려하기 위하여 공석 온도 영역까지 포함시켜 온도계측과 파괴실험 없이 순수한 이론만으로 고유변형도 영역을 결정하는 새로운 방법을 제안하였다. 이 방법으로 결정한 영역을 이용하여 판의 변형을 예측하고 실험 결과와 비교하여 잘 일치함으로써 본 논문에서 제안한 방법의 유효성을 입증하였다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.310-313
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• 2007

This paper covers finite element simulations to evaluate the bending limit of double pipe for tube-hydroforming. The tube-hydroforming process starts with a straight precut tube. The tube is often prebent in a rotary draw bending machine to fit the hydroforming tool. During the bending the tube undergoes significant deformation. So forming defects such as wrinkling, thinning and flattening are generated in the tube. Consequently we analyzed the effect of process parameters in rotary draw bending process and searched the optimized combination of process parameters to minimize the forming defects using orthogonal arrays. The characteristic to evaluate the effects of the process parameters is the bending angle which wrinkling is generated, we define the bending angle at that time as bending limit. Of many process parameters, the process parameters of the bending process such as gab between inner and outer tube, boosting force, dimensions of mandrel were analyzed. And we observed the deformation modes of bent double pipe at specific bending angle in each parameter combination.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 추계학술대회 논문집
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• pp.337-340
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• 2008

The cross section shape of intermediate die is one of important parameters to obtain dimensional accuracy of final product in shaped drawing process. Until now it has been designed by the experience or trial and error of the expert. In this study, the cross section shape of intermediate die fur spline shape is determined by the electronic field analysis, shape factor method. The result of the electronic field analysis, shape factor method has been compared with that of the present method. The effects of cross section shape on the dimensional accuracy were investigated by using FE analysis. And then the multi-stage shaped drawing experiments were performed to verify the results of FE analysis. As a result, the cross section shape from the electronic field analysis had the good dimensional accuracy. The electronic field analysis can be used for the method to obtain the cross section shape of intermediate die in shaped drawing process.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 추계학술대회 논문집
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• pp.53-56
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• 2009

Roll forming process is one of important metal processing technology because the process is simple and economical. These days, roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate for productivity. However, it is difficult to apply to the forming of micro scale or sub-micro scale pattern. In this study, the roll forming processing for the micro scale is designed and analyzed. In this study, the forming of micro pattern for solar cell plate by incremental roll forming process is analyzed. The solar cell plate may have thousands of patterns, and the analysis of forming considering all the patterns is impossible due to the computational costs. In this study, analyses are carried out for various numbers of patterns and the results are compared. It is shown that the analyses results with four row patterns and twelve row patterns are same. So, it is considered that the analysis can be carried out for only four rows of pattern for the design of incremental roll forming process. Also experiment is carried out process that is designed through simulation.

• 대한기계학회논문집A
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• 제29권2호
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• pp.253-261
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• 2005

In decades, a substantial body of work on a unified viscoplastic model which considers the mechanism of plastic deformation and creep deformation has developed. The systematic scheme for numerical analysis of unified model is necessary because the dominant failure mechanism is the defect growth and coalescence in materials. In the present study, the unified viscoplastic model for materials with defects suggested by Suquet and Michel was employed for numerical analysis. The constitutive equations are integrated based on the generalized mid-point rule and implemented into a finite element program (ABAQUS) by means of user-defined subroutine (UMAT). To evaluate the validity of the developed UMAT code and the assessment of the adopted viscoplastic model, the results obtained from the UMAT code was compared with the numerical reference solution and experimental data. The unit cell analysis also has been investigated to study the effect of strain rate, temperature, stress triaxiality and initial defect volume fraction on the growth and coalescence of the defect.

• 소성∙가공
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• 제28권6호
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• pp.347-353
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• 2019

The porthole extrusion process is a classic metal forming process to produce complex cross-section shaped aluminum profile. It is very difficult to design porthole die and extrusion process because of the complex shape of extrusion die and internal metal flow. The main variables in this process are ram speed, initial billet and tool temperature, and die shape. In general, the metal flow of porthole extrusion process can be divided into two steps. During the first step, the billet is divided into several parts in the porthole die bridge. During the second step, the divided billets are welded in the welding chamber. In the welding chamber, the level of welding pressure is very important for the quality of the final product. The purpose of this study is to increase the welding pressure in the welding chamber by using a two stage welding chamber. The porthole extrusion die was designed by using the Taguchi method with orthogonal array. The effectiveness of the optimized porthole die was verified by using the finite element analysis.

• 소성∙가공
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• 제7권3호
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• pp.233-245
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• 1998

A new approach has been proposed for the incremental analysis of the nonsteady state large deformation of planar anisotropic elastic-plastic sheet forming. A mathematical brief review of a constitutive law for the incremental deformation theory has been presented from flow theory using the minimum plastic work path for elastic-plastic material. Since the material embedded coordinate system(Lagrangian quantity) is used in the proposed theory the stress integration procedure is completely objective. A new return mapping algorithm has been also developed from the general midpoint rule so as to achieve numerically large strain increment by successive control of yield function residuals. Some numerical tests for the return mapping algorithm were performed using Barlat's six component anisotropic stress potential. Performance of the proposed algorithm was shown to be good and stable for a large strain increment, For planar anisotropic sheet forming updating algorithm of planar anisotropic axes has been newly proposed. In order to show the effectiveness and validity of the present formulation earing simulation for a cylindrical cup drawing and front fender stamping analysis are performed. From the results it has been shown that the present formulation can provide a good basis for analysis for analysis of elastic-plastic sheet metal forming processes.

• 소성∙가공
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• 제3권1호
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• pp.97-109
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• 1994

Closed-die forging of the spur gears with circular are fillet has been analyses by using the upper-bound method. A kinematically admissible velocity field has been developed, wherein, the tooth profile consists of the involute curve and the circular arc fillet. In the analysis, the deformation regions have been divided into eight zones. A constant frictional stress has been assumed on the contacting surfaces Utilizing the formulated velocity field, numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth, addendum modification coefficient and friction factor, on the relative forging pressure of spur gears. As the result of numerical calculations, the relative forging pressure does not change so much against the variation of module. On the other hand, the relative forging pressure increases at the final filling stage as the addendum modification coefficient increases.

• 대한기계학회논문집A
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• 제22권1호
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• pp.1-15
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• 1998

In this paper, thermo-viscoplastic finite element analysis of the effect of tool edge radius on cutting process are performed. The thermo-viscoplastic cutting model is capable of dealing with free chip geometry and chip-tool contact length. The coupling with thermal effects is also considered. Orthogonal cutting experiments are performed for 0.2% carbon steel with tools having 3 different edge radii and the tool forces are measured. The experimental results are discussed in comparison with the results of the FEM analysis. From the study, we confirm that this cutting model can well be applied to the cutting process considered the tool edge radius and that a major causes of the "size effect" is the tool edge radius. With numerical analysis, the effects of the tool edge radius on the stress distributions in workpiece, the temperature distributions in workpiece and tool, and the chip shape are investigated.estigated.