• Design & Manufacturing
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• v.10 no.3
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• pp.1-7
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• 2016

In the semiconductor industry the memory and chip were developed to high density memory and high performance chip, so circuit design was also high integrated and the test bed was needed to be thin and fine pitch socket. LGA(Land Grid Array) IC socket with thin wall thickness was designed to satisfy this requirement. The LGA IC socket plastic part was manufacture by injection molding process, it was needed accuracy, stiffness and suit resin with high flowability. After injection molding process the side gates were needed to remove for further assembly process. ln this study, the cold press cutting process was applied to remove the gates. For design of punch and die, the cold press cutting analysis was implemented by$DEFORM-2D^{TM}$ ln consideration of the simulation results, an adequate punch and die was designed and made for the cutting unit. In order to verify the performance of cutting process, the roughness of cutting section of the part was measured and was satisfied in requirement.

• Transactions of Materials Processing
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• v.14 no.2 s.74
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• pp.160-167
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• 2005

In the present study about extru-bending of angle product, the bending of extruded angle products with the $'\Lambda'$ section and 'ㄱ', section can be obtained using two extrusion billets by the hot metal extru-bending machine with the two punches moving in the different velocity. The bending curvature can be controlled by the different velocity of billets through the two-hole container. This paper describes simulations and experiments of extru-bending process that can make bending during extruding by the difference of stem velocities. And they are applied to two kinds of dies, that is, one of them is conical dies with symmetry $'\Lambda'$ section and the other one is conical dies with asymmetry 'ㄱ' section. The results of the forming simulation by $DEFORM^{TM}-3D$ and results of experiments show that the bending phenomenon at the die exit during extrusion can be obtained with two extrusion billet by the two stems moving in the different velocity. And it was known that it is possible to design the structure of conical cavity of extrusion dies and to control the curvature of product through the simulation and experiment of extru-bending process.

• Transactions of Materials Processing
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• v.13 no.1
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• pp.9-14
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• 2004

Recently, various bulk metallic glasses (BMG's) having good mechanical and chemical properties were developed. BMG's can easily be deformed in the supercooled liquid region, via viscous flow mechanism. By using the viscous flow, the very low pressure is needed to deform the materials. In this study, we investigated the structural transition and deformation behavior of Vitreloy 1 (Zr/sub 41.2/Ti/sub 13.8/Cu/sub 12.5/Ni/sub 10/Be/sub 22.5/) using TMA and DSC. We applied the results to the micro forming process. The forming condition was chosen based on the viscosity data from TMA, and Si wafer with micro patterns on the surface was used as a forming die. The deformed surface was analyzed by SEM and 3D Surface Profiling System. The alloy showed good replication of the patterns. Quantitative measurement of roughness was useful to evaluate the replication. Surface condition of the deformed surface was determined by the initial surface condition.

• Transactions of Materials Processing
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• v.21 no.8
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• pp.493-498
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• 2012

A wheel nut wrench is one of the hand tools used to loosen and tighten lug nuts on automobile wheels and it has generally a solid-type geometry for commercial vehicles. However, the solid-type wheel nut wrenches manufactured by hot forging processes exhibit several drawbacks such as heavy weight and rough surface finish. Thus, many efforts have been devoted to change the part geometry and improve the manufacturing process. For this purpose, the weight of the final product can be reduced drastically using a hollow tube as the initial stock, which can be manufactured by the more economical manufacturing process of cold forging. In this study, the cold forging of a hollow-type wheel nut wrench for commercial vehicles was designed based on the results of fundamental experiments and CAE analyses using the commercial finite element code DEFORM-3D. In addition, cold forging experiments were conducted on a special-purpose forming machine for hollow wheel nut wrenches in order to validate the designed process sequence. As results, it was found that the final products with a weight reduction of 39% and better surface appearance can be manufactured without any defect with the newly designed cold forging process.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.5 s.182
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• pp.51-58
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• 2006

The necessities for heightening fuel efficiency as well as lightweight design, lead to an increase of the use of aluminum alloys in the automobile industry. Extruded aluminum profile channels are used widely for the design of frame parts as lightweight assemblies, especially if a high stiffness is needed. While many applications can be realized with forming of hollow square-sectioned extruded profiles such as a stretch bending and a hydro-forming, some applications demand the use of a press bending which can be hardly found in the previous study. In this study, by introducing the use of a press bending into car sub-frames, the demands for higher accuracy as well as higher flexible method than the conventional methods will be satisfied. With respect to the design of sub-frames, the process planning was performed from the shape of a sub-frame product. The designed processes were analyzed by the commercial FEM code, DEFORM-3D. Forming dies for the each process were designed and prototypes of sub-frames were manufactured by the verified farming process. In addition, some of the important features of design parameters in the press bending were reviewed.

• Transactions of Materials Processing
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• v.26 no.5
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• pp.286-292
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• 2017

Magnesium alloy shows strong anisotropy and asymmetric behavior in tension and compression curve, especially at room temperature. These characteristics limit the application of finite element method (FEM) which is based on conventional continuum mechanics. To accurately predict the material behavior of magnesium alloy at microstructural level, a methodology of fully coupled multiscale simulation is presented and a crystal plasticity model as a constitutive equation in the simulation of metal forming process is introduced in this study. The existing constitutive equation for rigid plastic FEM is modified to accommodate deviatoric stress component and its derivatives with respect to strain rate components. Viscoplastic self-consistent (VPSC) polycrystal model was selected as a constitutive model because it was regarded as the most robust model compared to Taylor model or Sachs model. Stiffness matrix and load vector were derived based on the new approach and implemented into $DEFORM^{TM}-3D$ via a user subroutine handling stiffness matrix at an elemental level. The application to extrusion and rolling process of pure magnesium is presented in this study to assess the validity of the proposed multiscale process.

• Transactions of Materials Processing
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• v.22 no.4
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• pp.189-195
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• 2013

In this study, the weld strength of extru-rivet spot welding was investigated by simulation and experiment. In order to obtain hot plasticity flow bonding of the two plates by a single rivet, electrodes are used for heating of the two plates and the rivet by electric resistance. Because weld strength is influenced by the temperature in the weld zone, the diameter of the electrodes and the amount of current supplied to the electrodes are important variables. For the simulation, heat distribution and weld strength were calculated using DEFORM-3D. The weld strength in the weld zone was calculated for various values of the experimental parameters. The simulation results showed that the weld strength was the highest when the weld current was 37kA, the electrode diameter was 12mm, and the welding frequency was 90cycle. Aluminum 5052 was used for the experimental study. A total of three aluminum plates, two welding plates with 1mm thickness and one plate with 2mm thickness for the inserting rivet, were used for the experimental extru-rivet spot welding.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.50-52
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• 2007

Large size forged parts usually were made by hot open die forging because of the die cost, high applied load and small manufacturing quantities. Cast ingots were used in open die forging and the ingots almost included the cavities in its inside. Therefore, one of the aims for forging processes is to close and remove the cavities. However, its criteria were well not defined since the studies have many difficulties to investigate the cavity behaviors because of its large size. In this study, the cavity closure behavior was investigated by experimental and FE analysis. The FEM analysis is performed to investigate the overlap defect of cast ingots during free forging stage. The measured flow stress data were used to simulate the forging process of cast ingot using the practical material properties. Also the analysis of cavity closure is performed by using the $DEFORM^{TM}$-3D. The calculated results of cavity closure behavior are compared with the measured results before and after forging, which are scanned by the X-ray scanner. From this result, the criteria for deformation amounts effect on the cavity closure can be investigated by the comparison between practical experiment and numerical analysis.

• Journal of Advanced Marine Engineering and Technology
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• v.32 no.4
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• pp.585-595
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• 2008

Process design of multi-stage forging for a bolt with nonaxisymmetric washer cam has been studied by using finite element method. For shape complexity of the bolt, it is impossible to manufacture in a single stage forging. To design multi-stage forging for the bolt the forging load and fiber flow of each step have been analyzed by using commercial finite element code DEFORM-3D. Simulated results have been compared with experimental ones. Multi-stage forging process has been designed with four stages. The workpiece should be eccentric shape until third forging stage. And then bolt head and washer of eccentrical shape is created in last stage. As a results, It was predicted that shape of product would be good and effective strain would be uniformly distributed in the product. Also, it was predicted whether defects would exist or not by reviewing the fiber flow.

• Design & Manufacturing
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• v.10 no.2
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• pp.24-28
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• 2016

In this study, relevant to impact extrusion process of the rectangular batter case for electric vehicles, numerical and experimental analyses were conducted to reduce the earring defects induced in the unevenness of metal flow. Since the earring is caused by the non-uniform metal flow induced in the friction and aspect ratio in the bottom section. As a way to reduce the earring, variable land die concept was applied. In order to analyze numerically the complex metal flow by using commercial finite element package, DEFORM 3D, impact extrusion process was simplified in upsetting mode at bottom section and extrusion mode at land section. The impact extrusion experiments were conducted to verify the assessment of process parameter for impact extrusion. As results, variable land die which has longer longitudinal section makes reduce earring defects. In addition, it was confirmed that the effect that slug shape like dog-bone also can reduce the earring. This study is expected to be able to present the useful design guidelines for manufacturing the battery case.