• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.06a
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• pp.81-85
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• 2006

The characteristic of sheet metal process is the few loss of material during process, the short processing time and the excellent price and strength. The sheet metal process with above characteristic is common used in industrial field, but in order to analysis irregular field problems the reliable and economical analysis method is demanded. Finite element method is very effective method to simulate the forming processes with good prediction of the deformation behaviour. Among Finite element method, The static-implicit finite element method is applied effectively to analyze real-size auto-body panel stamping processes, which include the forming stage. In this paper, it was focussed on the drawability factors on auto-body panel stamping by AUTOFORM with using tool planing alloy to reduce law price as well as high precision from Design Optimization of die. According to this study, the results of simulation will give engineers good information to access the Design Optimization of die.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.2
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• pp.207-225
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• 1992

The study is concerned with the thermo-viscoplastic finite element analysis of axisymmetric forward hot extrusion through square dies. The problem is treated as a nonsteady state problem because the distribution of temperature and material properties are continuously changing with the punch travel. In square die extrusion, difficulties arise from the severe distortion and die interference of elements at the aperture rim of the die even with a small punch travel. And finite element computation is impossible without intermittent remeshing. Accordingly, an automatic remeshing technique is proposed by employing specially designed mesh structure near the aperture rim. The analysis of temperature distribution includes heat conduction through material interfaces, heat convection and radiation to the atmosphere and is carried out by decoupling the heat analysis from the analysis of the deformation. The extrusion load and the distributions of strain rate and temperature are computed for the given cases rendering reasonable results. Computed grid distortions are found to be in good agreement with the experimental results. It has been thus shown that the proposed method of analysis can be effectively applied to the axisymmetric hot extrusion through square dies.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.4
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• pp.452-462
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• 1985

The axisymmetric forward extrusion is analyzed by using the rigid-plastic finite element formulation. The distribution of stresses and strains as well as the deformation pattern in solid extrusion is very important for the improvement of product quality. The initial velocity field is determined by assuming the material as a Newtonian fluid through an arbitrarily shaped axisymmetric die. The workhardening effect and the friction of the die-material interface are considered in the formulation. Some reduction of area and die shapes(conical and biquadratic-curved) are chosen for computation. Experiments are carried out for steel alloy(SCM4) specimens using conical and curved dies. It is found that experimental observation is in good agreement with FEM results. The strain distribution is curved(biquadratic) dies is shown to be more uniform than in conical dies at the same reduction of area.

• Transactions of Materials Processing
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• v.19 no.4
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• pp.253-262
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• 2010

For multi-stage deep drawing process including ironing operation and biaxial forming in this study, tool developments are achieved, and the developed tool sets are applied to experimental investigations. In process and tool designs, a contact condition between intermediate blank and lower die is considered as the sequential one. In this study, the material used is cold-rolled thin sheet (SPCE) with the initial thickness of 0.4mm. From the experimental approaches, several failures such as tearing, localized thickening and thinning, are observed. To solve these failures, the contact surface on the lower die is modified. As the experimental results by applying the modified lower die, it is investigated that the failures are not occurred, and the excessive deformation behavior due to the thinning and thickening effects are decreased. Furthermore, the thickness distributions on the major axis and the minor axis of each intermediate blank are investigated to be already satisfied the target (ironing) thickness, respectively. By this systematic approach, it is confirmed that the experimental results show good agreements with the designed and required configuration of each deformed and final products.

• Transactions of Materials Processing
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• v.19 no.6
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• pp.352-356
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• 2010

This paper was designed to fabricate the micro-spur gear by the LIGA and hybrid powder extrusion process. It is important to manufacture a micro-die with a high aspect ratio and determine appropriate extrusion conditions for a microforming. Ni has been used to fabricate micro-dies. LIGA process was capable to produce micro-extrusion dies with close tolerance, longer bearing length and adequate surface quality. Superplastic Al-78Zn powders have the great advantage in achieving deformation under low stresses and exhibiting good micro-formability with average strain rate raging from $10^{-3}$ to $10^{-2} s^{-1}$ and constant temperature ranging from 503 to 563K. Al-78Zn powders were compacted into a cylindrical shape ($\Phi3\times$h10mm) under compressive force of 10kN and, subsequently, the compacted powders were extruded by the hybrid powder extrusion process controlling of the temperature holing time for a improvement on formability of Al-22Zn powder. Micro-extrusion has succeeded in forming micro-gear shafts.

• Journal of Korea Foundry Society
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• v.19 no.5
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• pp.410-418
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• 1999

To overcome the undesirable deformation, peeling off and geometrical restrictions which were mainly caused by differences in thermal expansion coefficients during the cladding of aluminum strip and stainless strip, new processing method based on vacuum die casting is designed and implemented in fabricating Fe-17wt%Cr steel (stainless steel). To increase cast-bonding ability, the surface of Fe-17wt%Cr steel is electrochemical etched to have optimum pit size (above 0.2 mm) and pit density (above 30%). The implementation of vacuum die casting by using surface treated stainless steel (Fe-17wt%Cr Steel) produces good trial products having acceptable cast-bonding ability. The enabling conditions for cast-bonding are pouring temperature $690^{\circ}C$, filling speed 30 m/sec and casting pressure $800\;kg/cm^2$. The microscopic observation of cast-bonded Al/Fe-17wt%Cr steel does not show any evidence of intermetallic compounds. The bonding strength of trial products is $150-400\;kg/cm^2$ and this is stronger than conventionally cladded metal having $30-70\;kg/cm^2$.

• Journal of the Korea Institute of Military Science and Technology
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• v.11 no.4
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• pp.83-91
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• 2008

The development of the equal channel angular pressing(ECAP) process in metals has recently provided a feasible solution to produce ultra-fine or nano-grained bulk materials with tailored material properties. However, ECAP process is difficult to scale up commercially due to requirements of an excessive load. In this paper, a new Hybrid-ECAP process with torsional die is considered to obtain materials of ultra-fine grain structure under low forming load. An upper bound analysis and numerical simulation (DEFORM 3D, a commercial FEM code) are carried out on the torsional die. By the upper bound analysis, analytical expression for the compression force and rotation speed are obtained. By the FEM analysis, the distribution of strain, stress and deformation are obtained. These results show that the Hybrid-ECAP is a useful process because this process can obtain the homogeneous deformations with relatively low forming load. Additionally, due to decreased forming load, die life can be improve.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.192-198
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• 2005

In this paper, a systematic attempt for estimating geometric dimensions of cold forgings is made by finite element method and a practical approach is presented. In the approach, the forging process is simulated by a rigid-plastic finite element method under the assumption that the die is rigid. With the information obtained from the forging simulation, die structural analysis and springback analysis of the material are carried out. In the springback analysis, both mechanical load and thermal load are considered. The mechanical load Is applied by unloading the forming load elastically and the thermal load is by cooling the increased temperature due to the plastic work to the room temperature. All the results are added to predict the final dimensions of the cold forged product. The predicted dimensions are compared with the experiments. The comparison has revealed that predicted results are acceptable in the application sense.

• Journal of the Korean Society for Precision Engineering
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• v.11 no.4
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• pp.58-68
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• 1994

An equilibrium approach is suggested as an effective tool for the analysis of sheet metal forming processes on the basis of force balance together with geometric relations and plasticity theroy. In computing a force balance equation, it is required to define a geometric curve approximating the shape of the sheet metal at any step of deformation from the geometric interaction between the die and the deforming sheet. Then the geometic informations for contacting and non-contacting sections of the sheet metal such as the number and length of both non-contact region, contact angle, and die radius of contact section are known from the geometric forming curve and utilized for optimization by force balance equation. In computation, the sheet material is assumed to be of normal amisotropy and rigid-phastic workhardening. It has been shown that there are good agreements between the equilibrium approach and FEM computation for the benchmark test example and auto-body panels whose sections can be assumed in plane-strain state. The proposed equilibrium approach can thus be used as a robust computational method in estimating the forming defects and forming severity rather quickly in the die design stage.

• Transactions of Materials Processing
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• v.33 no.1
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• pp.5-11
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• 2024

The development of a next-generation hydrogen compressor, a key component in the expansion of hydrogen charging infrastructure, is in progress. In order to improve compression efficiency and durability, it is important to optimize the precision forming and shearing processes of the diaphragm, which is the bellows unit cell, as well as the optimization of diaphragm shape itself. In this study, we aim to show that die and process design technology that can synchronize the inner and outer shearing points of the diaphragm for the precision forming of product can be constructed based on a numerical simulation. First, the damage model that can predict the fracture points will be determined using the shear load and shear zone measurements obtained by performing a blanking test of AISI-633 stainless steel. Next, we will explain the overall procedure based on numerical analysis model how to determine the shearing points according to the deformation pattern of urethane die for various shearing die design.