• 한국공작기계학회논문집
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• 제17권3호
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• pp.78-85
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• 2008

Roll forming process is one of the most widely used processes in the world for forming metals. It can manufacture goods of the uniform cross section throughout the continuous processing. However, process analysis is very difficult because of the inherent complexity. Therefore, time is consuming and much money are needed for manufacturing goods. In order to overcome this difficulty, a new computational method based on the rigid-plastic finite element method is developed for the analysis of roll forming process. In this paper, the design of roll forming process and the simulation are performed to manufacture the upper member at under rail composed of three members. The cold rolled carbon steel sheet(SCP-1) is used in this simulation, and a flow stress equation is set up by conducting the tensile test. The upper member is designed using two types of design for a excellent design. Each types are simulated and compared with the strain distribution using SHAPE-RF software. In addition, the numerical magnitude of bow and camber which are the buckling phenomenon is estimated.

• 한국산학기술학회논문지
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• 제18권6호
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• pp.395-399
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• 2017

자동차에 사용되는 LPI 연료필터 하우징 제품은 기존 다이캐스팅 공정에서 냉간 단조 공정으로 개발하여 경량화 및 내구성을 향상하였다. 하지만 T자형 단조 형상이기 때문에 제품을 생산하였을 경우 제품의 싱크 문제가 발생하게 된다. 이로 인해 제품의 후처리 가공 문제가 발생한다. 본 연구에서는 이러한 문제를 개선하기 위해 성형 해석 시뮬레이션을 이용해 문제를 예측하고 개선방안에 대해 연구했다. 성형 해석 시뮬레이션을 이용하여 문제를 개선하기 위해 완전 성형이 가능한 최적 블랭크의 부피를 결정하였다. 그리고 최적의 블랭크 부피에 맞춰 성형 해석 시뮬레이션을 수행하였고 싱크 현상을 가시화했다. 싱크 현상을 개선하기 위해 냉간 단조 공정 진행 시 싱크 부 밑 부분에 패드를 받침으로 싱크 현상을 개선하였다. 적정한 패드력을 구하기 위해 파라미터 스터디를 진행하였고, 적정한 패드력으로 공정 진행 시 싱크 문제를 개선하였다. 그리고 실제 산업 현장에 적용하여 싱크 문제 개선에 대한 검증을 수행했다.

• 소성∙가공
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• 제17권2호
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• pp.124-129
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• 2008

Net shape forging technologies give many effects into the costs and qualities for the finished products. So, the studies to reduce the additional machining amount are very important in forging industry. Specially, there are two main topics in cold forging industry, such as, tool life and precision forging. In this study, new forging technique was proposed to eliminate the machining process for fixing up the length and improve the lead accuracy of gear. The luck-up hub is manufactured through many processes, such as upsetting, piercing and direct extrusion. The gear is formed in direct extrusion process; however, lead accuracy of the gear is over allowance limit. Therefore, the additional sizing process must be added. In this study, process design for closed-die forging of a lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Design & Manufacturing
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• 제8권2호
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• pp.30-36
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• 2014

In this study, surface deformation patterns have been investigated by the rigid-plastic finite element method for friction factor test in solid cylinder compression process. AA1100 and AA6063 aluminum alloys, which show different work hardening characteristics respectively, have been adopted as model materials used for analysis. The main objective of this study is to provide the deformation mechanics in detail in solid cylinder compression process, especially at the die/workpiece interface that is closely related with the frictional conditions. For this reason, solid cylinder compression process has been numerically analyzed. The surface flow patterns at the contact boundary have been analyzed in terms of surface expansion, surface expansion velocity, pressure distributions exerted on the die surface along the die surface. By defining bulge factor, barreling phenomenon also have been examined with calibration curves to verify their effects on the surface flow pattern that is important for evaluating the frictional condition at the interface.

• Structural Engineering and Mechanics
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• 제41권6호
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• pp.805-822
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• 2012

Offshore pipelines have to withstand combined actions of tension and bending during deepwater installation, which can possibly lead to elliptical buckle and even catastrophic failure of whole pipeline. A 2D theoretical model initially proposed by Kyriakides and his co-workers which carried out buckling response analysis of elastic-plastic tubes under various load combinations, is further applied to investigate buckling behavior of offshore pipelines under combined tension and bending. In association with practical pipe-laying circumstances, two different types of loadings, i.e., bent over a rigid surface in the presence of tension, and bent freely in the presence of tension, are taken into account in present study. In order to verify the accuracy of the theoretical model, numerical simulations are implemented using a 3D finite element model within the framework of ABAQUS. Excellent agreement between the results validates the effectiveness of this theoretical method. Then, this theoretical model is used to study the effects of some important factors such as load type, loading path, geometric parameters and material properties etc. on buckling behavior of the pipes. Based upon parametric studies, a few significant conclusions are drawn, which offer a theoretical reference for design and installation monitoring of deepwater pipelines.

• 동력기계공학회지
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• 제16권6호
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• pp.52-58
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• 2012

Roll forming process is one of the most widely used processes in the world for forming metals such as a furniture drawer guide or an up and down slide guide. It can manufacture goods of the uniform cross section on a large scale throughout the continuous processing. In the domestic design and manufacture, roll forming process for production is taking most of the method of 2-point under rail slide. However, this method is vulnerable to the structural strength and stiffness is not suitable for high load conditions. Therefore, through systematic study of high load, low noise 3-point ball type of under rail slide its own design and manufacturing technology is the need to build. In this paper, to make center member of 3-point ball-type under rail slide for the refrigerator doors, the roll forming modeling and simulation are performed. Tensile test is performed about SCP-1 1/2H for determine the mechanical properties of materials. Modeling and simulation of roll forming is used MSC.MARC software of a dedicated analysis program used by rigid plastic finite element method. Interference between the roll and the final shape are predicted from the results of the simulation.

• 소성∙가공
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• 제16권8호
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• pp.603-613
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• 2007

This paper is concerned with joining of thin metal sheets by single stroke clinching process. This method has been used in sheet metal work as it is a simple process and offers the possibility of joining similar-dissimilar thin sheet metals. Clinching generates a joint by overlapping metal sheets deforming plastically by punching and squeezing sequence. AA 5754 aluminum alloy of 0.5 mm thick sheets have been selected as a modal material and the process has been simulated under different process conditions and the results have been analyzed in terms of the quality of clinch joints which are influenced mainly by tool geometries. The rigid-plastic finite element method is applied to analyses in this paper. Analysis is focused mainly on investigation of deformation and material flow patterns influenced by major geometrical parameters such as die diameter, die depth, groove width, and groove corner radius, respectively. To evaluate the quality of clinch joints, four controlling or evaluation parameters have been chosen and they are bottom, neck thickness of bottom and top sheets, and undercut thickness, respectively. It has been concluded from the simulation results that the die geometries such as die depth and diameters are the most decisive process parameters influencing on the quality of clinch joints, and the bottom thickness is the most important evaluation parameter to determine if the quality of clinch joints satisfies the demand for industrial application.

• 한국지반공학회논문집
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• 제19권3호
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• pp.53-64
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• 2003

사면을 포함한 경사지에 설치된 송전탑, 교각, 고층빌딩 등을 지지하는 말뚝은 풍하중, 지진, 차량 등에 의한 수평하중을 고려하여 설계되어야 한다. 이러한 사면이나 경사지에 설치된 수평하중을 받는 말뚝은 편평한 지반에 비하여, 수평지지력이 감소하기 때문이다. 그러므로 이러한 구조물은 일반적으로 강성이 높고, 대구경의 기초인 피어기초가 사용된다. 수평하중을 받는 피어기초는 일반적으로 장대말뚝과 다른 거동을 한다. 즉, 수평하중에 의하여 말뚝 자체의 회전이 발생하고, 그 회전의 중심점 상부의 사면측의 수동토압에 의존하여 지반파괴가 발생한다는 측면에서 짧은 강성 말뚝과 유사한 거동을 한다. 본 논문은 모래사면의 언덕 근처에 설치된 짧은 말뚝의 수평하중의 영향에 대한 실험 및 수치해석 결과를 포함한다. 대부분을 모형실험과 3차원 탄소성 유한요소해석의 비교, 결과를 기술하였다. 먼저, 사면 언덕에서 모형말뚝까지의 거리를 3종류로 구분하여 단항의 모형실험과 군항말뚝의 수평하중 특성을 파악하기 위하여 수평지반과 사면지반(경사 30$^{\circ}$)에 대하여 말뚝중심간의 거리를 각2종류로 모형실험을 실시하였다. 동시에 3차원 탄소성 유한요소법에 의한 수치해석을 통하여 모형실험의 결과와의 비교를 시도하였다. 사용된 모래지반은 배수조건하에서 삼축압축실험으로 재현하였다. 3차원 탄소성 유한요소해석에서 완전탄소성모델의 파괴기준은 Mohr-Coulomb식, 소성 포텐셜은 Drucker-Prage식을 이용한 MC-DP모델을 적용하였다. 연구결과, 3차원탄소성 유한요소법이 사질토 지반에 설치된 짧은 말뚝의 수평거동을 파악하는데 유효하다는 것을 확인하였다.

• 소성∙가공
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• 제16권7호
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• pp.521-529
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• 2007

This paper is concerned with the analysis on the surface expansion of AA 2024 and AA 1100 aluminum alloys in backward extrusion process. Due to heavy surface expansion appeared usually in the backward can extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the surface expansion is analyzed especially under various process conditions. The main goal of this study is to investigate the influence of degree of reduction in height, geometries of punch nose, friction and hardening characteristics of different aluminum alloys on the material flow and thus on the surface expansion on the working material. Two different materials are selected for investigation as model materials and they are AA 2024 and AA 1100 aluminum alloys. The geometrical parameters employed in analysis include punch corner radius and punch nose angle. The geometry of punch follows basically the recommendation of ICFG and some variations of punch geometry are adopted to obtain quantitative information on the effect of geometrical parameters on material flow. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward can extrusion process under different geometrical, material, and interface conditions. The simulation results are summarized in terms of surface expansion at different reduction in height, deformation patterns including pressure distributions along the interface between workpiece and punch, comparison of surface expansion between two model materials, geometrical and interfacial parametric effects on surface expansion, and load-stroke relationships.

• 한국지반신소재학회논문집
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• 제21권2호
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• pp.57-65
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• 2022

본 연구에서는 폭약과 발파공 사이의 충전매질을 통한 충격파 전파 효과를 수치적으로 시뮬레이션하고 검증하였다. 고체(Lagrangian)와 유체(Eulerian)를 혼합 모델링하기 위해 Arbitrary Lagrangian-Eulerian(ALE) 방법을 선택하였다. 시간의존적 해석은 발파공정 시간 동안 수행되었다. 폭약과 매질(공기 또는 물)을 유한 요소망으로 모델링하였고, 발파공은 시작점(폭약)에서 발파공벽에 도달하는 전파 속도와 충격력을 결정할 수 있는 강체로 가정하였다. 해석결과에 따르면 물의 전파속도와 충격력은 공기의 경우보다 컸다. 추가로 발파 작업의 실제 현장을 모델링하고 시뮬레이션하였다. 암석은 탄소성체로 가정하였다. 해석결과에 따르면 충전매질이 물인 경우 순간 충격력이 더 크고, 파쇄블록 크기는 더 작은 것으로 나타났다. 반면 발파공배면에서의 충격량은 물인 경우에 더 작았는데, 이는 파쇄에 충격에너지가 상당부분 사용되고, 파쇄로 인한 감쇠 효과에 의해 주변의 고체를 통한 압력 전파는 공기보다 작아지기 때문이다. 이로써 충전매질로서 물이 공기보다 경제성이 더 높다는 것이 입증되었다.