• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.2 s.233
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• pp.325-332
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• 2005

This paper presents a study on defects in pearlite lamella structure of high carbon steel by means of finite-element method(FEM) simulation. High carbon pearlite steel wire is characterized by its nano-sized microstructure feature of alternation ferrite and cementite. FEM simulation was performed based on a suitable FE model describing the boundary conditions and the exact material behavior. Due to the lamella structure in high carbon pearlite steel wire, material plastic behavior was taken into account on deformation of ferrite and cementite. The effects of many important parameters(reduction in area, semi-die angle, lamella spacing, cementite thickness) on wire drawing process can be predicted by DEFORM-2D. It is possible to obtain the important basic data which can be guaranteed in the ductility of high carbon steel wire by using FEM simulation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.311-314
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• 2003

Superconduction materials possess electrical/electronic and magnetic properties. Because superconduction materials is a ceramic powder, that can not be produced singlehandedly. So Ag sheathed Bi-2223 wire was produced by drawing process using powder-in-tube(PIT) method This superconductor has many difficulties to produce. The main difficulty is that the mechanical properties of the ceramic powder are very different from those of the Ag sheath. Actually, the fabrication of Ag sheathed Bi-2223 superconductor by PIT tends to lead to non-uniformity in the core thickness during drawing process. That is so called “Sausaging”. This study analyzed a sausaging using the finite-element method. Also, Effects of drawing process parameters on a sausaging has been carried out using finite element method. Finally, A way to prevent a sausaging has been discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.191-194
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• 2006

Recently the quality improvement of the steel cord product is demanded by the tire market. After wire drawing process, produced residual stresses have a harmful effect on the durability of the wire and become the cause which decreases the quality of the product. Therefore, to improve the quality of the steel cord product, the research regarding the method of residual stress relaxation is necessary. To evaluate the quality of the drawn wire, it is important to measure the residual stress, because the residual stress decides a variety of the quality level which is demanded in the drawn wire. This study proposed a residual stress relaxation method in the drawn wire using FE analysis. The validity of the analysis results was verified by nanoindentation test.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.08a
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• pp.27-36
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• 2004

Contemporary objectives for steel rod rolling processing are increasingly complex and often contrasting i.e. obtaining a desired product with optimum combination of properties such as strength, toughness and formability at lower cost. Low-alloy steel rods have been produced with several heat treatments for drawing and forging processes at room temperature. In order to reduce these heat treatments much of the researches concerning of high temperature mechanical behavior of steel rods have been conducted at wire rod mill of POSCO. In this present work, optimizations of rolling temperature and cooling rate for JS-SCM435 are performed to eliminate softening heat treatment(Low Temperature Annealing) for drawing process. The results from the optimization changed the microstructure of rods after rod rolling from Bainite with high tensile strength of 1000Mpa to Pearlite and Ferrite with appropriate strength of 750Mpa that is equivalent tensile strength after softening heat treatment.

• Transactions of Materials Processing
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• v.19 no.4
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• pp.224-229
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• 2010

During the multi-pass wire drawing process, wires suffer a great amount of plastic deformation that is through the cross-section. This generates tensile residual stress at surface of drawn wires. The generated residual stress on surface is one of the problems for quality of wires so that prediction and reduction of residual stresses is important to avoid unexpected fracture. Therefore, in this study, the effect of process variables such as semi-die angle, bearing length and reduction ratio on the residual stress was evaluated through Finite Element Analysis. Based on the results of the Analysis, a prediction model was established for predicting residual stress on the surface of high carbon steel(AISI1072, AISI1082). To identify the effectiveness of the proposed model, X-ray diffraction is used to measure the residual stresses on the surface. As the result of the comparison between calculated residual stresses and measured residual stresses, the model could be used to predict residual stresses in cold drawn wire.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.1
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• pp.116-122
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• 1996

In forming processes, die failure must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The die wear affects the tolerances of formed parts, metal flow and costs of processes etc. The only way to control these failures is to develop methods which allow prediction of the die wear and which are suited to be used in the design state in order to optimize the process. In this paper, wire drawing processes were simulated using the rigid-plastic finite element method and its results were used for predicting the die wear by Archard's wear model. The effects of the temperature rising on the wear profiles of die were also investigated. The simulation results were compared with the measured die profiles.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.3
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• pp.295-302
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• 2013

The two cross-roll straightening process at room temperature is a manufacturing method for improving the straightness of a drawn wire. The distribution and magnitude of the internal and surface residual stresses of the drawn wire are changed after the wire-drawing process through the two cross-rolls; this also results in a change in the diameter of the drawn wire. The remaining residual stresses of the drawn wire after the wire-drawing dimensional changes were analyzed according to the distance between the rolls, oblique angle between the axes of the roll and the wire, predicted residual stresses, and dimensional change in the final product. The oblique angle between the concave and convex rolls did not affect the residual stresses or dimensional change, but the distance between rolls did.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.27-30
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• 2004

Clad wire , which has the advantages of the high strength of a steel core and the electro-conductivity, corrosion resistance of a copper layer, is widely being used the telecommunications, electric-electronic and military technology industries, among others. It is important to obtain uniform coated rate when producing clad wires. Clad wire drawing process can be influenced on damage and coated rate of core and sleeve by process variables as semi-die angle and reduction in area. Therefore, in this study, the finite-element results established in previous study is used to analyze the effect of the various forming parameters, which included the semi-die angle, reduction in area etc. The coated rate will be predicted with observation copper coated rate variation according to total reduction in area and the optimal pass schedule will be set up through proper reduction in area and semi-die angle variation.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.834-837
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• 2005

This study presents a study on the influence of process parameters(semi-die angle, die reduction, friction condition, and bearing length) in drawn wire on residual stresses were investigated using FE-analysis. In this study, semi-die angle and die reduction have a significant effect on the residual stresses at the surface of drawn wire. In the previous study, in order to reduce the residual stresses, several methods were suggested: addition of axial tension, application of skin pass, straightening in multi-roll straightener etc. In this study, it can be known that the concurrent application of skin pass with low die reduction and low semi-die angle at the final stage of drawing operation reduces dramatically the both axial and hoop residual stresses after drawing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.144-147
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• 1997

Process design of multi-step wire drawing process, conducted by means of finite element analysis and ANN(Artificial Neural Network), has been considered. The investigated problem involves the adequate selection of the drawing die angle and the correspondent reduction rate sequence in the condition of desired initial and final diameter. Combinations of the process parameters which are used in finite element simulation are selected by using orthogonal array. Also the orthogonal array and the results of finite element simulation which are related to the process energy are used as train data of ANN. In this study, it is shown that the new technique using ANN is useful method in application to the wide range of metal forming process.