• Transactions of Materials Processing
• /
• v.28 no.2
• /
• pp.83-88
• /
• 2019

This paper introduces a new concept - on-line FE model, as applied to metal rolling. The new technology allows for completion of process simulation within a tiny fraction of a second without loss of high-level prediction accuracy inherent to FEM. The three steps of an on-line FE model design namely, process metamorphosis, mesh design, and process variable design, are described in detail. The procedure is demonstrated step by step through designing actual on-line models for the prediction of the dog-bone profile in edge rolling. The validity and prediction accuracy of the on-line FE models are analyzed and discussed.

• Transactions of Materials Processing
• /
• v.11 no.7
• /
• pp.589-595
• /
• 2002

Up to now, Collimators have been generally produced by handwork and only a few companies have produced by semi-automatic system. Under this situation, automatic system for assembly of optical collimator has risen as a most essential technique in the development of optical communication components. In this study, it was constructed to develop optical collimators with high functionality and We manufactured optical collimators with a GRIN rod lens using automatic system. Therefore, we worked a performance test through a comparison of collimators made by automatic system and handwork with angle alignment, beam size. Also we compared common product with auto-manufactured sample. As a result, it brought a reduction of the tact time and an improvement of an efficiency and a productivity of optical collimators. therefore it was found that automatic system was indispensable for materialization of optical collimators with high functionality.

• Transactions of Materials Processing
• /
• v.11 no.5
• /
• pp.414-422
• /
• 2002

Most of numerical analyses for injection molding have been based on the Hele Shaw's approximation: two-dimensional flow analysis. In some cases, that approximation causes significant errors due to loss of geometrical information as well as simplification of the flow characteristics along the thickness direction. The present work covers numerical analyses of injection molding using three-dimensional solid elements. The accuracy of the analysis results has been verified through some numerical examples in comparison with the classical shell-based approach. The Proposed approach is then applied to predict product defects and to improve flow characteristics for a precision electronics part. In addition, design of experiment has been utilized in order to find the optimal process conditions for better product quality.

• Transactions of Materials Processing
• /
• v.13 no.2
• /
• pp.137-141
• /
• 2004

The large deformation at cryogenic temperature is expected as one of the effective methods to produce large bulk ultrafine grained materials. The effects of annealing temperature, 150∼$300^{\circ}C$, on microstructures and mechanical properties of the sheets received 85% reduction at cryogenic temperature were investigated, in comparison with those at room temperature. Annealing of 5083 Al alloy deformed 85%, at $200^{\circ}C$ for an hour,. resulted in the considerable increase of tensile elongation without the great loss of strength and the occurrence of equiaxed grains less than 300nm in diameter.

• Transactions of Materials Processing
• /
• v.10 no.2
• /
• pp.151-159
• /
• 2001

Flow defect of a piston-pin for automobile parts is investigated in this study. In combined cold extrusion of piston-pin, lapping defect, which is a kind of flow defect, appears by the dead metal zone. This appearance evidently happens in products with a thin thickness to be pierced for the dimensional accuracy and the decrease of material loss. The flow defect that occurs in piston-pin has bad effects on the strength and the fatigue life of piston-pin. Therefore, it is important to predict and prevent defects in the early stage of process design. The best method that can prevent flow defect is removing or reducing dead metal zone through material flow control. The finite element simulations are applied to analyze the flow defect. This study proposes processes for preventing flow defect by removing dead metal zone. Then the results are compared with the experimental ones for verification. These FE simulation results are in good agreement with the experimental ones.

• Transactions of Materials Processing
• /
• v.17 no.5
• /
• pp.350-355
• /
• 2008

Currently, in the automotive industry, the efforts to reduce the manufacturing cost by changing the manufacturing process are continually performed. In this paper, we proposed a new manufacturing process, the roll bending process of a ring plate of automotive fuel tank instead of conventional press blanking process to reduce material loss and manufacturing cost. Finite element analysis was used to optimize the roll bending process to assure rectangular cross-section of the ring plate. Also, spring-back analysis after the roll bending process was performed and dimension of the bending die considering spring-back was analyzed. Finally, we verified a possibility for realization of the proposed method with prototypes.

• Transactions of Materials Processing
• /
• v.18 no.6
• /
• pp.444-447
• /
• 2009

Piston crown to the hot forge a unified nature of the product has a shape with multi-level step forging process, so if you are not a mechanical professional, this process could lead to a significant loss to the material. Therefore, material technology in minor terms; continue to improve the collection rate that undamaged the product material. The piston crown and the manufacturing products such as marine diesel engines are being forged to reduce costs and to improve mechanical properties. Piston crown molding is a hot forging process that works in large volume forging products. Because of the size of the hard plastic material flow process for improving the design and actual field experience through advanced plastic technology, it is important to interpret the results. Also for many experimental plastic procedures, the accumulation of results is very important.

• Transactions of Materials Processing
• /
• v.11 no.7
• /
• pp.569-574
• /
• 2002

Recently, thick PZT films are required for the cases of micro piezoelectric devices with high driving force, high breakdown voltage and high sensitivity, and so on. In this work, thick PZT films were fabricated by Sol-Gel multi-coating method. Microstructures, and electrical properties of films were investigated by XRD, FESEM, impedance analyzer, and P-E hysteresis. PZT films with 2.7$mu extrm{m}$ to 4.4${\mu}{\textrm}{m}$ thickness were fabricated. Dielectric constant, loss, remnant polarization and coercive field of them were 880~1650 at 1kHz, 2~3% at 1kHz, 26~32 $\mu$C/$ extrm{cm}^2$, and 33~60kV/cm, respectively. Also a transverse piezoelectric coefficient $(e_{31,f})$ measurement system was fabricated and tested for thick film samples.

• Transactions of Materials Processing
• /
• v.20 no.4
• /
• pp.291-295
• /
• 2011

The injector housing has two functions, namely, positioning the injector and protecting it from coolant. The conventional manufacturing process of the injector housing by machining has some drawbacks such as considerable loss of material and environmental pollution caused by excessive use of cutting oil. In this paper, precision cold forging is proposed as a new manufacturing process in order to improve these issues. A numerical study was conducted to compute the metal flow, strain, load and other process variables using DEFORM-2D, a finite element analysis(FEA) code for metal forming. Two process methods were investigated and optimal conditions were computed with the FEA code. A prototype was manufactured from the optimal process method and the metal flow and hardness were obtained from the prototype.

• Transactions of Materials Processing
• /
• v.8 no.1
• /
• pp.47-56
• /
• 1999

The governing functional in plastic deformation has to satisfy the incompressibility constraint. This incompressibility constraint imposed on velocity fields can be removed by introducing either Lagrange multiplier or the penalty constant into the functional. In this study, two-dimensional rigid plastic FEM programs using these schemes were developed. These two programs and DEFORM were applied in a cylinder upsetting and a closed die forging to compare the values of load, local mean stress and volume loss. As the results, the program using Lagrange multiplier obtained a more exact and stable solution, but it took more computational time than the program using the penalty constant. Therefore, according to user's need, one of these two programs can be chosen to simulate a metal forming processes.