• Transactions of Materials Processing
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• v.13 no.2
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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.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.439-446
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• 2002

This study presents a new computational model to analyze the grain deformation in a polycrystalline aggregate in a discrete manner and based directly in the underlying physical micro-mechanisms. When scaling down a metal forming process, the dimensions of the workpiece decrease but the microstructure of the workpiece remains the similar. Since the dimensions of the workpiece are very small, the microstructure especially the grain size will play an important role in micro forming, which is called size effects. As a result, specific characteristics have to be considered for the numerical analysis. The grains and grain boundary elements are introduced to model individual grains and grain boundary facets, respectively, to consider the size effects in the micro forming. The constitutive description of the grain elements accounts for the rigid-plastic and the grain boundary elements for visco-elastic relationships. The capability of the proposed approach is demonstrated through application of grain element and grain boundary element in the micro forming.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.10
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• pp.76-83
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• 2001

This paper is concerned with the analysis of the forming characteristics of radial-backward extrusion. The single action pressing is analyzed by using the rigid-plastic FEM. The design factors such as die corner radius, gap height, and friction factor are involved in the simulation. The analysis is focused on the influences of the design factors on the maximum punch farce and metal flow into can and flange region. As a result of analysis, the gap height among the design factors is known to have a major effect on the metal flow of radial-backward extrusion for single action pressing compared with other design factors. As is expected, forming load and volume of flange increase as gap height and die corner radius increase, respectively.

• Transactions of Materials Processing
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• v.9 no.2
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• pp.152-158
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• 2000

A finite element analysis has been performed to investigate the effect of die clearance on shear planes in the fine blanking of a part of automobile safety belt. For the analysis, S45C is selected as an material, which is used in manufacturing the part of automobile safety belt, and Cockcroft-Latham fracture criterion is applied. Effect of die Clearance on die-roll width, die-roll depth, burnish zone, and fracture zone has been investigated in the finite element analysis by a rigid-plastic FEM code, DEFORM-2D. From the analysis, it has been found that die-roll depth and depth of the shear plane increase with increasing die clearance. And the burnish zone decreases with increasing die clearance, but the variation of fracture zone is opposite to that of burnish zone because the increase in die clearance requires less fracture energy. Theoretical predictions are compared with experimental results. There is a good agreement between theory and experiment.

• Transactions of Materials Processing
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• v.5 no.2
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• pp.105-114
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• 1996

Recently, precision forging techniques are applied to manufacture spur gears. Compared to conventional machining, they produce parts of better mechanical properties and less residual stresses with a much higher production rate. In the present investigation a rigid-plastic three dimensional finite element method was applied to analyze hot forging and cold sizing of a spur gear by closed dies. The involute curve of a tooth profile was approximated by a circle close to the curve. Results of the analyses make it possible to predict local strengths of the gear die failure and an appropriate preform for cold sizing. It was found that the preform for cold sizing. It was found that the preform for the cold sizing is the most important because it determines whether the gears especially teeth can be successfully formed.

• Journal of the Korean Society of Mechanical Technology
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• v.20 no.6
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• pp.894-900
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• 2018

Among the soft ground improvement methods, PBD is the most common construction method because it is cheap and construction is fast. However, if the ground is rigid, additional work is required. In this study, the structural safety, natural vibration, and safety angle of the steel vertical tower structure were evaluated in the development of the PBD composite perforator which can be combined with drilling work and PBD construction. Structural safety was assessed when the wind load of 20 m/s was simultaneously applied to the PBD construction load of 20 tons, the perforating operation of 25 tons, and the wind speed of 50 m/s was applied only to the wind load. The natural frequencies were evaluated up to the sixth mode, and the safety angle was evaluated for static and dynamic safety angles.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.22-28
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• 2000

By using the finite element method, the Oyane's ductile fracture integral I was calculated from the histories of stress and strain according to every element and then the forming limit of hydroforming process could be evaluated. The fracture initiation site and the forming limit for two typical hydroforming processes, tee extrusion and bumper rail under different forming conditions are predicted in this study. For tee extrusion hydroforming process, the pressure level has significant influence on the forming limit. When the expansion area is backed by a supporter and bulged, the process would be more stable and the possibility of bursting failure is reduced. For bumper rail, the ductile fracture integral i is not only affected by the process parameters, but also by the shape of preforming blank. Due to no axial feeding on the end side of the blank, the possibility of cracking in hydroforming of the bumper rail is influenced by the friction condition more strongly than that of the tee extrusion. All the simulation results show reasonable plastic deformation, and the applications of the method could be extended to a wide range of hydroforming processes.

• Geotechnical Engineering
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• v.4 no.1
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• pp.49-58
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• 1988

The stresses on the buried steel pipe under embankment are analysed by the elasto-plastic theory using FEM to study the influences of the geometry of soil-conduit pipe system and the elastic modulus of the fill on the pipe responses . The geometry of the system considered in this study includes the height of embankment, the thickness of the pipe, and the width and the depth of the trench . By comparing the stresses computed by Marston-Spangler's pipe theory with those obtained from the elasto-plastic theory, Marston-Spangler's theory was discussed and analysed . It is found that the stress distribution around the pipe by elasto- plastic analysis is similar to that by Spangler's flexible pipe theory when the geometrical ratio (diameter/thickness) of the steel pipe is 400. And Spangler's flexible pipe theory does not seem to be suitable to analyse the buried steel pipe of which the geometrical ratio is lower than 200. The vertical loads by the rigid pipe theory are always larger than those by the flexible pipe theory regardness of the variations in the geometry of soil-conduit pipe system considered above and the elastic modulus of the fill.

• Transactions of the Korean Society of Mechanical Engineers
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• v.8 no.5
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• pp.435-441
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• 1984

The matrix method, as an effective FEM formulation for the analysis of rigid-plastic deformation, was applied to the bore expanding of anisotropic sheet metal. The effect of planar anisotropy on sheet metal deformation was studied for bore expanding process under the uniform radial stretching condition, and the results were compared with isotropic and normal anisotropic solutions. Experiments were carried out using a flat punch for cold-rolled sheet metal. The experimental results were compared with computations from the matrix method with the boundary conditions corresponding to actual experiment. Both in theory and experiment, it is found that the maximum thinning which results in necking occurs in the direction of the minimum R-value. The results also suggest that the matrix method is efficient for analyzing planar anisotropic sheet metal. The comparison between theory and experiment suggests that Hill's theory of planar anisotropy is somewhat exaggerated. However, the theoretical predictions are in qualitative agreement with the experimental results.

• Transactions of Materials Processing
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• v.18 no.1
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• pp.52-58
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• 2009

Generally, a vertical rolling process is used to achieve extensive width reduction in hot strip mill. However, it is impossible to avoid the defects such as dog-bone and edge-seam defect. The sizing press process has been developed in response to the defects mentioned above. Especially, this study is carried out to investigate the deformation of slab by two-step sizing press. The deformation behavior of slab in the sizing press process is more favorable than that in conventional vertical rolling edger. The FE-simulation is applied to predict the deformation behavior of the slab. In this paper, the several causes of the asymmetrical deformation are mentioned for the purpose of understanding of the anvil shape. Load, dog-bone and edge-seam defect are discussed in width sizing process considering the anvil shape. And to reduce the problems generated at rougher mill just after sizing press, these are studied in this paper. The deformation behavior of slabs and optimum anvil shape are obtained by rigid-plastic finite element analyses and neural network.