• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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• pp.233-236
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• 2004

The major objective of this paper is to clarify the effect of constitutive laws on bulk forming design based on the ideal flow theory. The latter theory is in general applicable for perfectly/plastic materials. However, its kinematics equations constitute a closed-form system, which are valid for any incompressible materials, therefore enabling us to extend design solutions based on the perfectly/plastic constitutive law to more realistic laws with rate sensitive hardening behavior. In the present paper, several constitutive laws commonly accepted for the modeling of cold and hot metal forming processes are considered and the effect of these laws on one particular plane-strain design is demonstrated. The closed form solution obtained describes a non-trivial nonsteady ideal process. The design solutions based on the ideal flow theory are not unique. To achieve the uniqueness, the criterion that the plastic work required to deform the initial shape of a given class of shapes into a prescribed final shape attains its minimum is adopted. Comparison with a non-ideal process is also made.

• 소성∙가공
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• 제14권9호통권81호
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• pp.798-803
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• 2005

In this paper, the six sigma scheme together with the rigid-viscoplastic finite element method is employed to obtain the optimal metal flow lines of a hot forging according to the six sigma processes, i.e., five steps such as define, measure, analyze, improve and control. Each step is investigated in detail to meet customer's requirements through improvement of product quality. A forging simulator is used for analysis of the metal flow lines of the hot forging, manufactured by a hot press forging machine, under various conditions of major factors determined at each step. The analyzed results are examined in order to reveal the effects of major factors on the metal flow lines and the formed shapes. The effects are then used to find an optimal process and the optimal process with die is devised and tested. The comparison between the required metal flow lines and the experiments shows that the approach is effective for optimal process design in hot forging considering metal flow lines.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2006년도 춘계학술대회 논문집
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• pp.417-420
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• 2006

The composition and structure of dendrite phase within $Zr_{76.11}Ti_{4.20}Cu_{4.51}Ni_{3.16}Be_{1.49}Nb_{10.53}$ bulk metallic glass (BMG) were confirmed by using an EPMA, XRD and TEM, respectively. The chief elements of dendrite phase were Zr-Ti-Nb and had a BCC structure. The thermal properties of this BMG have been then subsequently investigated by using a differential scanning calorimeter (DSC). The glass transition and crystallization onset temperatures were determined as $339.7^{\circ}C$ and $375.8^{\circ}C$ for this alloy, respectively. Mechanical properties have also been examined by conducting a series of uniaxial compression tests at various temperatures within supercooled liquid region under the strain rates between $10^{-4}/s$ and $3{\times}10^{-2}/s$. The deformation behavior of BMG composite within supercooled liquid region is similar to one of Vit-1 exhibiting amorphous single phase alloy. The flow stresses of BMG composite, however, are entirely higher than those of Vit-1 because dendrite phases are interfere with moving of atoms.

• 한국전산구조공학회논문집
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• 제14권1호
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• pp.65-76
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• 2001

본 연구의 목적은 평판의 모서리 둔각이 135도까지를 갖는 재료적 비선형 경사평판을 해석하기 위해 C°-계층적 평판요소를 개발하는 것이다. 기하학적 변환을 통해 경사진 경계조건은 직각좌표계의 좌표변환을 이용하여 해결할 수 있다. 여기서, 경사경계는 경사진 변 전체 또는 경사교량의 교좌위치와 관련된 몇 개의 선택지점만을 고려할 수 있게 하였다. 이 목적을 위해 경사교량의 교좌장치의 이동방향을 설명할 수 있도록 1차 전단변형을 갖는 Reissner/Mindlin 평판이론에 기초를 둔 5-자유도 경사평판요소가 정식화되었다. 한편, 평판의 극한내하력을 추정하기 위해 von-Mises 항복기준에 기초를 둔 소성유동법칙을 갖는 증분소성이론이 채택되었다. 또한, ADINA 소프트웨어에 의한 h-version 모델과 제안된 p-version 모델을 사용하여 경사각, 경계조건과 하중의 변화에 따른 영향을 조사하였다. 해석결과는 이론값과 문헌에 보고된 수치해석값과 비교되었다. 자유도 수에 따른 정확도를 비교기준으로 한다면, 본 연구에서 제안된 해석모델은 지금까지 개발된 가장 효율적 도구의 하나라고 할 수 있다.

• 소성∙가공
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• 제13권1호
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• pp.33-38
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• 2004

A new approach for the design of extrusion die surface of arbitrarily shaped section is presented. In order to generate the extrusion die surface. an automatic surface construction method based on B-spline surface and scalar field theory is proposed. The isothermal lines and stream lines designed in the scalar field are introduced to find the control points which are used in constructing B-spline surfaces. Intersected points between the isothermal lines and stream lines are used to construct B-spline surfaces. The inlet and outlet profiles are precisely described with B-spline curves by using the centripetal method for uniform parameterization. The extrusion die surface is generated by using the cubic curve interpolation in the u- and v-directions. A quantitative measure for the control of surface is suggested by introducing the tangential vectors at the inlet and outlet sections. To verify the validity and effectiveness of the proposed method, automatic surface generation is carried out for extrusion dies of arbitrarily shaped sections.

• 소성∙가공
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• 제18권8호
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• pp.640-645
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• 2009

Recently, boss and rib test based on backward extrusion process was proposed to quantitatively evaluate the interfacial friction condition in bulk forming process. In this test, the tube-shaped punch with hole pressurizes the workpiece so that the boss and rib are formed along the hole and outer surface of the punch. It was experimentally and numerically revealed that the height of boss is higher than that of the rib under the severe friction condition. This work is focused on the effect of the punch design and flow stress on deformation pattern in boss and rib test. From the boss and rib test simulations, it was found that there is slight variation in both the heights of boss and rib according to the length of punch land, nose radius, and face angle. However the hole diameter of the punch and the clearance between the punch and die have a significant influence on the calibration curves showing the heights of the boss and rib. In addition, the effect of flow stress on the calibration curves was investigated through FE simulations. It was found that there is no effect of strength coefficient of the workpiece on the calibration curves for estimation of friction condition. On the other hand, the strain-hardening exponent of the workpiece has a significant influence on the calibration curve.

• 소성∙가공
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• 제9권6호
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• pp.653-662
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• 2000

Wrinkling is one of the major defects in sheet metal products together with tearing, springback and other geometric and surface defects. The initiation and growth of wrinkles are influenced by many factors such as stress ratios, mechanical properties of the sheet material, geometry of the workpiece, contact condition, etc. It is difficult to analyze the wrinkling initiation and growth considering all the factors because the effects of the factors are very complex and the wrinkling behavior may show a wide scatter of data even for small deviations of factors. The finite element analyses of the wrinkling initiation and growth in the sheet metal forming process provide the detailed information about the wrinkling behavior of sheet metal. The direct analyses of the wrinkling initiation and growth, however, bring about a little difficulty in complex industrial problems because it needs large memory size and long computation time. In the present study, therefore, a global-local analysis technique is introduced for the computational efficiency. Through the analysis of wrinkling in the door inner stamping process, the efficiency of the global-local analysis technique is investigated.

• 소성∙가공
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• 제20권5호
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• pp.362-368
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• 2011

For the purpose of improving crashworthiness qualities and maximizing weight saving efficiency, TWB's(tailor welded blanks) of quench-hardenable boron steel sheet formed by hot stamping processes has been used for automotive BIW (body in white) applications. In this work, the flow behaviors of TWB of quench-hardenable boron steel sheet were investigated in uniaxial tension tests at elevated temperature. TWB's having a uniform thickness of 1.4mm were fabricated by laser welding. Specimens with two weld line directions were used to test the mechanical property and reliability of the weld zone. After heating at $950^{\circ}C$ for 5min, the specimens were subjected to tension test at 650, 700 and $800^{\circ}C$ with a strain rate of 0.01 /s and at $700^{\circ}C$ with strain rates of 0.01, 0.1 and 1/s. The ultimate strength of the weld zones was higher than that of the base materials at 650 and $700^{\circ}C$, but was similar to the base metal at $800^{\circ}C$. Fracture occurred at the base material at 650 and $700^{\circ}C$, but at the weld zone at $800^{\circ}C$.

• 소성∙가공
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• 제9권1호
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• pp.72-79
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• 2000

Dynamic recrystallization (DRX), which may occur during hot deformation, is important for the microsturctural evolution of 304 stainless steel. Especially, the current interest in modelling hot rolling demands quantitative relationships among the thermomechanical process variables, such as strain, temperature, strain rate, and etc. Thus, this paper individually presents the relationships for flow stress and volume fraction of DRX as a function of processing variables using torsion tests. The hot torsion tests of 304 stainless steel were performed at the temperature range of 900~110$0^{\circ}C$ and the strain rate range of 5x10-2~5s-1 to study the high temperature softening behavior. For the exact prediction of flow stress, the equation was divided into two regions, the work hardening (WH) and dynamic recovery (DRV) region and the DRX region. Especially, The flow stress of DRX region could be expressed by using the volume fraction of DRX (XDRX). Since XDRX was consisted of the critical strain($\varepsilon$c) for initiation of dynamic recrystallization (DRX) and the strain for maximum softening rate ($\varepsilon$*), that were related with the evolution of microstructure. The calculated results predicted the flow stress and the microstructure of the alloy at any deformation conditions well.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.199-202
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• 2005

In this paper, the six sigma scheme is employed together with the rigid-viscoplastic finite element method to obtain the optimal metal flow lines in hot press forging. In general, the six sigma process is consisted of following five steps : define, measure, analyze, improve and control. Each step Is investigated in detail to meet customer's requirements through improvement of product quality. A forging simulator, AFDEX-2D, is used for analysis of the metal flow lines of a multi-stage hot forging process under various conditions of major factors, determined at each step of the six sigma process. The analyzed results are examined in order to reveal the effects of major factors on the metal flow lines and the formed shapes. The effects are used to find an optimal process and the optimal process with die is devised and tested. The comparison between required metal flow lines and experiments shows that the approach is effective for optimal process in hot forging design considering metal flow lines.