• Transactions of Materials Processing
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• v.23 no.3
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• pp.159-163
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• 2014

In the current study, the effect of small surface defects in the starting material including roughness, indentations, or scratches, which are perpendicular to the direction of drawing, on the product quality is investigated using the finite element method. An axisymmetric defect is assumed. Such defects are defined by a cylindrical defect area and two tapered regions connecting the defect area to the non-defective area of the material. Various conditions for these initial surface defects are considered, including defect depth, defect slope and defect length. To describe the plastic deformation of the defect in detail during the simulation, local remeshing is applied. Based on the finite element results, defect disappearance maps were generated. It was found that defect disappearance is significantly dependent on the defect depth and the defect length coupled with the defect slope.

• Transactions of Materials Processing
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• v.13 no.1
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• pp.78-83
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• 2004

High-temperature superconduction materials(Bi2223) possess electrical/electronic and magnetic properties. Because high-temperature superconduction materials is a ceramic powder, that cannot be produced singlehandedly. So Ag sheathed Bi-2223 wire was produced by drawing process using powder-in-tube(PIT) method. This superconductor has many difficulties to produce. The main difficulty is that the mechanical properties of the ceramic powder are very different from those of the Ag sheath. And by these properties, Bi2223 high-temperature superconductor, which has a single filament drawing process and multi-filament drawing process, has a defect like sausaging and bursting at a center. This study analyzed multi-filament drawing process by FEM, and a defect generated during multi-filament drawing was studied by FEH. Specially, in order to prevent a bursting at a center, this study presented a method that inserts a pure Ag at a center of multi-filament wire

• Transactions of Materials Processing
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• v.21 no.5
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• pp.291-297
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• 2012

In this paper, the effect of back tension in multi-pass drawing or wiredrawing on the central bursting defect is investigated using finite element predictions. A rigid-plastic finite element method was used together with the McClintock damage model. Central bursting defects under different back tension stress values ranging from 0% to 20% of the yield strength of the material were predicted and they were compared to understand the effect of the back tension stress values on the central bursting defect. It is found that the level of back tension has a strong influence on the cumulative damage. Thus, higher back tension raises the possibility of the central bursting defect occurring, even though it decreases the interfacial pressure between the die and the work piece.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.273-276
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• 2003

High-temperature superconduction materials(Bi2223) possess electrical/electronic and magnetic properties. Because high-temperature superconduction materials is a ceramic powder, that can not be produced singlehandedly. So Ag sheathed Bi-2223 wire was produced by drawing process using powder-in-tube(PIT) method. This superconductor has many difficulties to produce. The main difficulty is that the mechanical properties of the ceramic powder are very different from those of the Ag sheath. Bi2223 high-temperature superconductivity have a single filament drawing process, and multi-filament drawing process. This study analysed multi-filament drawing process by FEM, a defects during multi-filament drawing was studied by FEM.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.10a
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• pp.107-117
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• 1994

A design methodology is applied for manufacturing a disk-brake piston component and a washing machine container. The design criteria are the limit drawing ratio and the forging load within the available press limit. Also, the final product should not have any geometrical defect. The rigid-plastic and elastic-plastic FEM have been applied to simulate both of the conventional manufacturing processes, respectively, which include deep drawing and forging process. Simulations of one stage process from a selected stock to the final product shape are performed for generating information on additional requirements for metal flow. The best manufacturing processes are selected, which is using a hemispherical punch in the deep drawing process for both disk-brake piston component and washing machine container.

• Transactions of Materials Processing
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• v.3 no.2
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• pp.178-188
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• 1994

A design methodology is applied for manufacturing a disk-brake piston component. The design criteria are the limit drawing ratio and the forging load within the available press limit. Also, the final product should not have any geometrical defect. The rigid-plastic FEM has been applied to simulate the conventional four stage manufacturing processes, which include deep drawing and forging process. Simulation of one stage process from a selected stock to the final product shape is performed for generating information on additional requirements for metal flow. Two stage forming processes with different punch corner and nose geometries are also simulated to identify the possible best solutions. Finally, the best manufacturing process is selected, which is using a hemispherical punch int he deep drawing process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.450-453
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• 2008

During the drawing of reentrant section like a spline, the unfilled in the corner of dies or the bended product emerges from the large reduction of area, the complex shaped sections and other nonuniform properties in material and lubrication conditions. In this study, the drawing of the spline section with the non-rotary symmetry from a circular aluminum billet has been analyzed by using commercial code DEFORM-3D. A new die construction method preventing the spline from the drawback of bending and the unfilled defect has been suggested and verified through the analysis using centroid shift method and the hybrid construction between converged and diverged profile.

• Transactions of Materials Processing
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• v.24 no.2
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• pp.115-120
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• 2015

Deep drawing of cylindrical cups is one of the most fundamental and important processes in sheet metal forming. Circular cups are widely used in industrial fields such as automobile and electronic appliances. Some of these cups are formed by a one-stage process, others such as battery cases and beverage cans are made by a multi-stage process. In the current study the multi-stage deep drawing of aluminum sheet metal is examined. The process consists of two deep drawing operations followed by two ironing operations. The press die, which can be used for the four-stage forming process, was manufactured allowing punch and die components to be easily changed for various experiments. The rolling direction of both the sheet and the drawn cups was always positioned toward the horizontal x-direction on the die face to minimize experimental errors during the progressive forming. The dimensional accuracy of the cylindrical cups formed at each stage and the earing defect due to the anisotropy of sheet were investigated. The influence of anisotropy on the thickness distribution was also examined. Both the thickness and the outer diameter of the cups were measured and compared for each set of experimental conditions. It was found that the dimensional accuracy of cups rapidly improves by employing the ironing process and also by increasing the amount of ironing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.274-284
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• 2002

Deep drawing process for rectangular drawn section is different with that for axisymmetric circular one. Therefore deep drawing process for rectangular drawn section requires several intermediate steps to generate the final configuration without any significant defect. In this study, finite element analysis for multi-stage deep drawing process for high precision rectangular cases is carried out especially for an extreme aspect ratio. The analysis is performed using rigid-plastic finite element method with an explicit time integration scheme of the commercial program, LS-DYNA3D. The sheet blank is modeled using eight-node continuum brick elements. The results of analysis show that the irregular contact condition between blank and die affects the occurrence of failure, and the difference of aspect ratio in the drawn section leads to non-uniform metal flow, which may cause failure. A series of experiments for multi-stage deep drawing process for the rectangular cases are conducted, and the deformation configuration and the thickness distribution of the drawn rectangular cases are investigated by comparing with the results of the numerical analysis. The numerical analysis with an explicit time integration scheme shows good agreement with the experimental observation.

• Design & Manufacturing
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• v.15 no.3
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• pp.13-18
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• 2021

In plate forming technology, cylindrical drawing process is widely used in industry due to technological development. In this study, we used stainless steel 3042B and stainless steel 304J1, which are the most commonly used materials in the production of cold and hot water tanks for water purifiers, among cylindrical drawing products. Under the same conditions, the thickness of the sidewall of the product formed by drawn experiment was studied. As a result of the experiment, the bottom thickness of stainless steel 304J1 was considered to be thick. It is judged that the defect rate can be reduced by changing the breaking phenomenon of the floor surface of the cold and hot water bottles to the material of stainless steel 304j1. Stainless steel 304 2B material shows a sharp change in thickness from punch corner R to sidewall position, while stainless steel 304J1 material showed a uniform change from punch corner R to sidewall position. Stainless steel 304J1 material is considered to improve the clamping of the product in the process of extracting the product after hand drawing. The appearance of stainless steel 3042B products is considered to produce more wrinkles in the flange, which exerts greater tensile force on the sidewall during molding, resulting in uneven sidewall thickness.