• Journal of the Korean Society for Precision Engineering
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• v.22 no.3 s.168
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• pp.86-92
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• 2005

In this paper a forward-backward can extrusion process are analyzed by using rigid-plastic FEM simulation. FEM simulation is conducted to investigate forming characteristics such as deformation modes fur different process parameters. Design parameters such as thickness ratio, punch angle, friction factor and diameter ratio are selected to study the effect of them on the pattern of material flow. The analysis is focused mainly on the influences of the design factors on deformation pattern in terms of forming load, extruded length ratio and volume ratio. It is known for the simulation that the forming load, the length ratio and the volume ratio increase as the thickness ratio (TR), the wall thickness in forward direction to that in backward direction, decreases. The various punch angles have slight influence on the forming load. length ratio and volume ratio. However friction factor have little effect on the forming characteristics such as the forming load, volume ratio and so on. In addition the forming load increases as diameter ratio (DR), the outer diameter of a can in forward direction to that in backward direction, increases. Furthermore the extruded length ratio is lowest with a certain value of DR=0.85 among diameter ratios. Pressure distribution exerted on the die-material interface is illustrated schematically.

• Design & Manufacturing
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• v.2 no.2
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• pp.43-47
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• 2008

This paper is concerned with the analysis of material flow characteristics of stepped rod forming. The analysis in this paper concentrated on the evaluation of the design parameters for deformation patterns of tube forming, load characteristics, extruded length, and die pressure. The design factors such as punch nose radius, die corner radius, friction factor, and punch face angle are involved in the simulation. The stepped rod forming is analyzed by using a commercial finite element code. This simulation makes use of stepped rod material and punch geometry on the basis of punch geometry recommended by International Cold Forging Group. As radius ratio is large, forming load was reduced but extruded length ratio was increased.

• Transactions of Materials Processing
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• v.21 no.4
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• pp.234-239
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• 2012

This study examines the forming properties and forming loads needed to increase the edge thickness on the external face of a plate using finite element analysis(FEA). Recently, forming optimization techniques within FEA are being extensively used in designing the optimal forming conditions for processes like forging, extrusion, rolling, and spinning. Most of these existing forming operations involve reducing the volume per unit length, but research for increasing volume per unit length is not very extensive. For this study we chose an automotive engine flywheel which is a welded assembly of a plate and a gear with each component having a different thickness. We considered a forming technique to increase the thickness in order to allow the machining of the gear directly on the external face of plate alleviating the need for a weld. To study various forming techniques, we used the finite element method with the flow stress of material and incremental forming steps. We conclude from this study that the analysis of forming properties and forming loads by using the finite element analysis and testing is useful as a method to increase the thickness per unit length.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.9
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• pp.96-103
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• 1999

A kinematically admissible velocity field is derived to analyze the forming load and the extruded length in the extrusion/forging process of trochoidally headed bars from round billets. The forming load and the extruded length are obtained by minimizing the total energy-consumption rate. Experiments are carried out with lead billets at room temperature using trochoidally shaped punches. The theoretical predictions of forming load and extruded length are in good agreement with the experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.8
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• pp.151-156
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• 2000

A kinematically-admissible velocity field is proposed to determine the forming load the average extruded length and the velocity distribution in the forward and backward extrusion process of a socket. Experiments are carried out with antimony-lead billets at room temperature using the rectangular punch and the hexagonal die. The theoretical predictions of the forming load and the average extruded length are in good agreement with the experimental results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.73-82
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• 2016

Recently, automobile industries have been developing many structural automotive parts made of thin, high-strength steel strips to produce safer and more environmentally friendly cars. The roll forming process has been considered one of the most efficient processes in manufacturing high-strength steel parts because it is a high-speed process that forms sheets in increments. However, most automotive parts vary longitudinally in their cross-sections. Therefore, it is difficult to apply the roll forming process to automotive parts made of high-strength steel. A variable section roll forming process has been proposed in recent studies. The rotational axes of the forming rolls are fixed, and the forming rolls have three-dimensional shape. As such, the cross-section of the part varies linearly along its length, and the angle between the bend line and longitudinal axis is less than 1 degree. Thus, the rate of cross-sectional variation along the length is relatively small. In this study, the rate of cross-sectional change along the length of a forming roll has been increased. Moreover, the angle between the bend line and longitudinal axis has been increased up to 15 degrees. The variable sections of the forming rolls have been designed for high strength steel parts with a symmetric u-type cross-section that varies linearly and symmetrically along the longitudinal axis.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.8 s.239
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• pp.1139-1145
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• 2005

Most failures of ductile materials in metal forming processes occurred due to material damage evolution - void nucleation, growth and coalescence. In this paper, the modified yield function of Liao et al in conjunction with the Hosford's yield criterion is studied to clarify the plastic deformation characteristic of voided anisotropic sheet metals. The void growth of an anisotropic sheet under biaxial tensile loading and damage effect of void growth on forming limits of sheet metals are investigated. Also the characteristic length defining the neck geometry is introduced in M-K model to incorporate the effect of triaxial stress in necked region on forming limits. The forming limits theoretically predicted are compared with experimental data. Satisfactory agreement was obtained between the predictions and experimental data.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.1129-1133
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• 2001

An upper bound elemental technique(UBET) has been carried out to predict the forming load, the deformation pattern and the extruded length of the lateral extrusion of a spider for the automotive universal joint. For the upper bound analysis, a kinematically admissible velocity field(KAVF) is proposed. From the proposed velocity field, the upper bound load, the deformation pattern and the average length of the extruded billets are determined by minimizing the total energy consumption rate which is a function of unknown velocities at each element. Experiments are carried out with antimony-lead billets at room temperature using the rectangular shaped punch. The theoretical prediction of the forming load, the deformation pattern and the extruded length are good in agreement with the experimental results.

• Design & Manufacturing
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• v.9 no.2
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• pp.16-19
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• 2015

In this paper, The experimental study on the crack during press forming of the door latch assembly for a vehicle door is performed. Length to be inserted into the conventional mold upper die punch is 20 mm, wherein the cracks are generated on the product surface and causes a secondary quality problem. In this study, the length to be inserted in the mold upper die punch 0 mm, 10 mm, 20 mm, which was changed to perform the experiment. Through the experiment, the length inserted into the mold can be seen that the upper die punch of the press forming conditions optimized when the 0 mm.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.1
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• pp.154-161
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• 2001

A UBET analysis has been carried out to predict the forming load and the extruded length of forward and backward extrusion of hexagonal and trochoidal wrench colts. For the upper bound load and the average length of the extruded billets are determined by minimizing the total energy consumption rate which is a function of unknown velocities and parameters at each element. Experiments are carried out with antimony-lead billets at room temperature using hexagonal and trochoidal shaped punches. The theoretical predictions of the forming load and the extruded length are in good agreement with the experimetal results.