• 대한기계학회논문집A
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• 제20권10호
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• pp.3031-3037
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• 1996

In cold forming processes, due to high working pressure action on the die surface, failure mechanics must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. Die wear affects the tolerances of formed parts, metal flow and costs of process etc. The only way to control these failures into devlop methods which allow prediction of die wear and which are suited to be used in the design state in order to optimize the process. In this paper, the forming propcesses that involve cold forward extrusion and wire drawing were simulated by rigid plastic finite element method and its output were used for predicting die wear by Archard wear model. The simulation results were compared with the measured worn dies.

• 대한화학회지
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• 제23권5호
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• pp.329-337
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• 1979

국내에서 상업용으로 이용하는 여러종류의 고분자 필름들에 대한 투습도를 일정한 압력과 상대습도 하에서 측정하고 투습도의 역수를 구하여 각 필름의 방습도로 정의하였다. 실험온도 $40{\pm}1^{\circ}C$, 상대습도 $90{\pm}2%$ 하에서 시료를 24시간 방치한 후 컵방법으로 필름의 방습도를 측정한 결과 다음과 같은 순서로 감소함을 밝혔다. 연신 polypropylene (O. PP) > 고밀도 polyethylene (HDPE, Inflation) > 고밀도 polyethylene (HDPE, T-die) > 무연신 polypeopylene (C. PP) > 무연신 polyester (N. PET) > 저밀도 polyethylene (LDPE) > 연신 polyester (O.PET) > 경질 polyvinyl chloride (Rigid PVC) > 반경질 polyvinyl chloride (Semirigid PVC) > 연질 Polyvinyl chloride (Nonrigid PVC) > 연신 nylon(O.Nylon) > 무연신 nylon (N.Nylon) 또한 온도증가에 따라서 측정한 결과 방습도는 HDPE, (T-die) > C. PP > O. PET > LDPE > O. Nylon으로 감소하였고, LDPE, HDPE (T-die), C. PP, O. PET, O. Nylon 필름들의 투습활성화 에너지는 12.0, 11.1, 11.4, 11.7, 14.1 kcal/mole임을 밝혔다. 필름의 투습도는 극성증가에 따라서 증가하고 PVC 필름은 가소제 첨가에 따라서 증가하며, 필름 두께와 연신 증가에 따라서는 감소하였다. O. PP/LDPE, N.Nylon/LDPE, C.PP/LDPE이 집합필름은 단일필름보다 두께에 대한 의존성이 증가하였다.

• 한국정밀공학회지
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• 제17권3호
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• pp.33-38
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• 2000

In process of tube spinning far shock absorber on vehicles, the selection of feed rate and rounding radius of forming roller and revolution speed of tube and forming roller, forming gap between die and forming roller are very important factors to obtain the optimal process result. In this paper, rigid-plastic FEM and UBET analysis are applied to verify effect of each factors by forming load. We can obtain the optimal conditions to prevent defects during processing.

• Design & Manufacturing
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• 제7권1호
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• pp.11-18
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• 2013

This paper presents the plastic inhomogeneous deformation behavior of bimetal composite rods during the axisymmetric and steady-state extrusion process through a conical die. The rigid-plastic FE model considering frictional contact problem was used to analyze the co-extrusion process with material combinations of Cu/Al. Different cases of initial geometry shape for composite material were simulated under different conditions of co-extrusion process, which includes the interference and frictional conditions. The main design parameters influencing on deformation pattern are diameter ratio of the composite components and semi-die angle. Efforts are focused on the deformation patterns, velocity gradient, predicted forming load and the end distance through the various simulations. Simulation results indicate that there is an obvious difference of forming pattern with various diameter ratio and semi-die angle. The analysis in this paper is concentrated on the evaluation of the design parameters on the deformation pattern of composite rod.

• 소성∙가공
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• 제4권3호
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• pp.267-281
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• 1995

Preform design is one of the critical fields in metal forming. The finite element method(FEM) has been effective in designing preforms and process sequence, for which the backward tracing scheme of the rigid-plastic FEM has been explored. In this work a program using the backward tracing scheme by the rigid-plastic FEM is developed for three-dimensional plastic deformation, which is an extension of the scheme from two-dimensional cases. The calculation of friction between workpiece and die, and handling of boundary conditions during backward tracing require sophisticated treatment. The developed program is applied to upsetting of a rectangular block and to side pressing of a cylindrical workpiece. The results of the two applications show feasibility of the program on three-dimensional plastic deformation.

• 대한기계학회논문집
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• 제16권3호
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• pp.453-458
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• 1992

본 연구에서는 유한요소법에 바탕을 둔 최적공정설계법을 이용하여 압출 금형 형상의 최적설계를 실시하였다.설계의 결과를 참고문헌에서 발췌한 이론해와 비교 하였으며, 축대칭 압출공정에서 압하율, 마찰, 재료특성 등이 금형의 최적형상에 미치 는 영향에 대하여 조사하였다.

• 한국정밀공학회지
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• 제9권2호
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• pp.116-121
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• 1992

The optimal extrusion process for the rate sensitive materials have been developed in this study. The preliminary designs of the die shapes have been carried out to maintain constant strain rate during extrusion and the upper bound approach has been applied to define the process variables (the die entrance velocity and the die length) including the rheology during deformation. The result for the axisymmetric extrusion process has been verified with rigid-viscoplastic finite element analysis. It has been confirmed that the optimal die has wider band of constant strain rate than the conical one does.

• 소성∙가공
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• 제9권3호
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• pp.265-273
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• 2000

The conventional and new forging processes of the power steering worm blank are analyzed by the rigid-plastic finite element method. The conventional process contains three stages such as indentation, extrusion and upsetting, which was designed by a forming equipment expert. Process conditions such as reduction in area, semi-die angle and upsetting ratio are considered to prevent internal or geometrical defects. The results of simulation of the conventional forging process are summarized in terms of deformation patterns, load-stroke relationships and die pressures for each forming operation. Based on the simulation results of the current three-stage, the power steering worm blank forging process for improving the conventional process sequence is designed. Die pressures and forming loads of proposed process are within limit value which is proposed by experts and the proposed process is found to be proper for manufacturing the power steering worm blank.

• 한국정밀공학회지
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• 제12권1호
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• pp.29-37
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• 1995

In many metal forming processes, it is common to use stress rings for reducing elastic deformation and failures of forming dies. But, shrink fit of dies inner diameter of die insert, machining is reuqired after shrink fit processes. The reduction of inner diameter can be predicted by the analysis of elastic-plastic finite element method. The dimension of dies before shrink fit can be determined to minimize or remove machining after shrink fit processes by deformation analysis of die. The computation of contacting stresses along die surface was analyzied by rigid plasitic finite element method, and data were interpolated by the contact search algorithm. In this paper, we propose the analysis method of forging dies after shrink fit and forming to improve dimensional accuracy of final products.

• 소성∙가공
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• 제13권2호
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• pp.148-153
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• 2004

Finite element analysis of open die forging process to make rectangular billet has been performed in this study. Three dimensional rigid-plastic finite element method was used to analyze the effects of process variables, forging pass design and die configurations on the void closure phenomena to maximize the internal deformation for better structural homogeneity and center-line consolidation of the rectangular billet. The effect of anvil width ratio, anvil pitch, anvil shape and number of pass has been estimated by the degree of void closure ratio. Although it is difficult to optimize process parameters in the operational environments, favourable process conditions are suggested for better product quality.