• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.03a
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• pp.129-136
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• 1994

Differential side bevel gears have been produced by machining process, but recently cold forging process for the bevel gear is under development in domestic industry. This study presents the possibility to form not only bevel gear but also spline gear at the same time using the experiment and numerical analysis. The preform shape is designed to form both bevel gear and spline gear simultaneously by the backward tracing scheme of the rigid-plastic finite element method(FEM). The experimental results confirm that the numerically-designed preform is satisfactory to form both bevel gear and spline gear. It is noted that the backward tracing scheme is helpful in designing preforms.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.428-431
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• 2005

This paper describes the process design for hot forging of bearing hub. Forging processes of bearing hub are simulated using the rigid-plastic finite element method. In the process called closed die forging without flash, the design of blocker geometry is of critical importance. Forging processes designs are take advantage of computer aided Process planning and experts. But that is difficult to predict metal flow line. So the preform is designed by the expert, and modified through predict metal flow line by CAE. This paper is to approach preform design considered defect such as metal flow and unfitting etc. at the finisher process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.361-364
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• 2008

Incremental forming path to manufacture a thick concave steel plate using the line array roll set is designed. To find the optimum forming path, the forming processes are simulated by the finite element method. A general-purpose commercial software, MSC.MARC is used. The rolls are modeled as rigid surfaces and the thick plate is modeled as 8-node hexahedral elastic-plastic solid elements to predict accurate springback. It is found that the process can be successfully applied to the fabrication of the dual curvature ship hull plate

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04a
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• pp.596-602
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• 1995

In this paper, the rolling-sliding contact problem of a layered semi-infinite solid compressed by a rigid surface is solved by finite element method based on the elasto-plastic theory. The purpose of this paper is to present the standard that is needed the later design. For this analysis, the principal parameters are layer thickness. Young's modulus ratio of layer and substrate and friction coefficient. In particular, this paper is interested in effect that layer thickness have influence upon displacement and shear and tensile stress at interface. For the layered material, the layer and the substrate behave elastic and linear-strain hardening respectively. For law friction, a relatively thin layer reduce the undesired maximum tensial stress but, for high friction, act contrary to the case of low friction.

• Nuclear Engineering and Technology
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• v.54 no.1
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• pp.326-342
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• 2022

Comparative analyses of a shield building subjected to a large commercial aircraft impact between decoupling method and coupling method are performed in this paper. The decoupling method is applying impact force time-history curves on impact area of the shield building to study impact damage effects on structure. The coupling method is using a model including aircraft and shield building to perform simulation of the entire impact process. Impact force time-history curves of the fuselage, wing and engine and their total impact force time-history curve are obtained by the entire aircraft normally impacting the rigid wall. Taking aircraft structure and impact progress into account some loading areas are determined to perform some comparative analyses between decoupling method and coupling method, the calculation results including displacement, plastic strain of concrete and stress of steel plate in impact area are given. If the loading area is determined unreasonably, it will be difficult to assess impact damage of impact area even though the accurate impact force of each part of aircraft obtained already. The coupling method presented at last in this paper can more reasonably evaluate the dynamic response of the shield building than the decoupling methods used in the current nuclear engineering design.

• Design & Manufacturing
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• v.7 no.1
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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.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.3
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• pp.483-492
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• 1998

An inverse analysis been applied to obtain the flow stress of the material. In this method, a ring-shaped specimen is compressed between two flat tools. This procedure employs, as the object function of inverse analysis, the balance of measured loads and reaction forces calculated by using rigid-plastic finite element method. The balance is explicit scalar function of flow stress which is a function of some unknown constants. For minimizing the balance, Newton-Raphon scheme is used. The friction factor, m, between flat tools and the specimen is determined by using friction area-divided method. The proposed method allows an accurate identification by avoiding the usual assumptions made in order to convert experimental measures into stress-strain relation. In this paper, the proposed method is numerically tested. A commercial pure aluminum was selected, as an example, to apply the method and the results are compared with stress-strain relation obtained by experiments.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.292-296
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• 2008

A new method of evaluating critical damage values of commercial materials is presented in this paper. The method is based on the previous study of the methodology [1] of acquisition of true stress-strain curves or flow stress curves over large strain from the tensile test in which the flow stress is described by the Hollomon law-like form, that is, by the strain dependent strength coefficient and the strain hardening exponent. The strain hardening exponent is calculated from the true strain at the necking point to meet the Considere condition. The strength coefficient is assumed to be constant before necking and represented by a piecewise linear function of strain after necking. With the predicted flow stress, a tensile test is simulated by a rigid-plastic finite element method with higher accuracy of less than 0.5% error between experiments and predictions. The instant when the fracture begins and thus the critical damage is obtained is determined by observing the stress variation at the necked region. It is assumed that the fracture due to damage begins when the pattern of stress around the necked region changes radically. The method is applied to evaluate the critical damage of a low carbon steel.

• Journal of Korean Society of Steel Construction
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• v.23 no.4
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• pp.429-438
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• 2011

In this study, the explicit numerical algorithm was proposed to simulate the stress erection process and ultimate-load analysis of the strarch (stressed arch) system. The strarch system is a unique and innovative structural system and member prestress comprising prefabricated plane truss frames erected through a post-tensioning stress erection procedure. The flexible bottom chord, which has sleeve and gap details, is closed by the reaction force of the prestressing tendon. The prestress imposed on the tendon will enable the strarch system to be erected. This post-tensioning process is called "stress erection process." During this process, plastic rigid-body rotation occurs to the flexible top chord due to the excessive amount of plastic strain, and the structural characteristic is unstable. In this study, the dynamic relaxation method (DRM) was adopted to calculate the nonlinear equilibrium equation of the system, and a displacement-based finite-element-formulated filament beam element was used to simulate the nonlinear behavior of the top chord sections of the strarch system. The section of the filament beam element was composed by the amount of filaments, which can be modeled by various material models. The Ramberg-Osgood and bilinear kinematic elastic plastic material models were formulated for the nonlinear material behaviors of the filaments. The numerical results that were obtained in the present study were compared with the experiment results of the stress erection and with the results of the ultimate-load analysis of the strarch unit frame. The results of the present studies are in good agreement with the previous experiment results, and the explicit DRM enabled the analysis of the post-buckling behaviors of the strarch unit frame.

• Design & Manufacturing
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• v.7 no.1
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• pp.28-33
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• 2013

During the cold forming, due to high working pressure acting 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. The mechanisms of wear are consisted of adhesion, abrasion, erosion and so on. Die wear affects the tolerances of formed parts, metal flow, and costs of process. The only way to control these failures is to develop a prediction method on die wear suitable in the design state in order to optimize the process. The wear system is used to analyse 'operating variables' and 'system structure'. In this study, with AISI D2, AISI 1020, AISI 304SS materials, a series of the wear experiments of pin-on-disk type to obtain the wear coefficients from Archard's wear model and the upsetting processes are carried out to observe the wear phenomenon during the cold forming process. The analysis of upsetting processes are performed by the rigid-plastic finite element method. The result of the analysis is used to investigate the die wear the processes, and the analysis simulated die wear profiles are compared with the experimental measured die wear profiles.