• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.246-249
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• 1998

In the present study, domain decomposition using the substructuring method is developed for the computational efficiency of the finite element analysis of metal forming processes. In order to avoid calculation of an inverse matrix during the substructuring procedure, the modified Cholesky decomposition method is implemented. As obtaining the data independence by the substructuring method, the program is easily parallelized using the Parallel Virtual Machine(PVM) library on a workstation cluster connected on networks. A numerical example for a simple upsetting is calculated and the speed-up ratio with respect to various domain decompositions and number of processors. Comparing the results, it is concluded that the improvement of performance is obtained through the proposed method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.56-61
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• 2008

Cropping metal materials is widely used for feeding processes of various forming method, such as forging, extrusion, drawing, and upsetting. However, cropping has many weak points, which are material loss in part of cutting, chip creation, and much use of lubrication oil, etc. In this study, instead of cropping, a novel process is proposed to cut metal materials, especially stainless steel bar which is known very difficult to crop. Results of FE-analysis will be shown to verify the proposed method comparing with those of the conventional cropping process. Also, fitting products were successfully forged using the fabricated billet by the proposed process.

• Transactions of Materials Processing
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• v.6 no.4
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• pp.319-328
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• 1997

A flow stress involving strain, solid fraction, and breakage ratio, and solid fraction updating algorithm were proposed to depict the deformation behavior of materials at the semi-solid state. In case of isothermally simple upsetting of Sn-15%Pb alloy at the semi-solid state, by comparing the results of finite element analysis with the existing experimental results, the reliability of both the developed flow stress and updating algorithm were investigated. It was found that the verified program can effectively be used in the rigid-viscoplastic finite element analysis of the semi-solid forging processes.

• Transactions of Materials Processing
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• v.19 no.8
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• pp.508-516
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• 2010

Thickening process in sheet metal forming is being increased to improve the strength as well as to reduce manufacturing process such as welding. This process can make it possible to obtain part locally thicker than that of initial sheet thickness. In this study, design method for manufacturing the component which has double sinks with local thickened wall is proposed. Deep drawing and upsetting processes are applied in order to form double sinks and thicken its walls. Used material is SPHC440 with the thickness of 2.0mm and initial blank size is determined on the basis of the final product. Distance between the center of double sinks and first drawing ratio to avoid fracture are the most significant factors during deep drawing. FE-analysis is implemented in order to determine the appropriate values. Progressive die is designed based on the proposed method and FE-analysis. As a result of experiment, locally thickened component can be manufactured, which has double sinks with the thickness about 3mm at the corner and wall.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.2 s.95
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• pp.87-94
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• 1999

The automated die design program is developed for cold forging of axisymmetric parts which are mainly produced by forward extrusion, backward extrusion, composite extrusion and upsetting. For this study, firstly classification of forged parts and investigation of die construction type usually employed in forging industry are carried out and the most proper type from several kinds of die construction is proposed as a standardized one. Based on the die design rules summarized in the references such as handbooks, technical papers, monthly journals, etc. the automated die design program was made using AutoLISP language available in AutoCAD software of personal computer. This program interactively runs for only input data, for example, forging process, shape of forged parts, type of punch, split of die insert and design of shrinkage rings and then displays details of drawings necessary to make a forging die. When a variety of forging processes and forged parts are tested to examine the validity of this program, it was confirmed to give good results applicable to the forging die design in press shop.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.173-176
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• 2007

The characteristics of the tool system give many effects into the costs and qualities for the finished components. This study proposes a new method for manufacturing of high manufacturing productivity, production process reduction and low cost through back pressure forming. The Lock-up hub is manufactured through many processes, such as upsetting($1^{st}$ Forming), piercing, direct extrusion($2^{nd}$ Forming), final sizing process($3^{rd}$ Forming). 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.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.5
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• pp.1166-1180
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• 1990

The study is concerned with the two-dimensional thermo-viscoplastic finite element analysis for radial forging as an incremental forging process. The deformation and temperature distribution of the workpiece during radial forging are studied. The analysis of deformation and the analysis of heat transfer are carried out for simple upsetting of cylinder by decoupling the above two analyses. A method of treatment for heat transfer through the contact region between the die and the workpiece is suggested, in which remeshing of the die elements is not necessary. Radial forging of a mild steel cylinder at the elevated temperature is subjected to the decoupled finite element analysis as well as to the experiment. The computed results in deformation, load and temperature distribution are found to be in good agreement with the experimental observations. As an example of viscoplastic decoupled analysis of hot radial forging, forging of a square section into a circular section is treated. The stresses, strains, strain rates and temperature distribution are computed by superposing material properties as the workpiece is rotated and forged incrementally. It was been thus shown that proposed method of analysis can be effectively applied to the hot radial forging processes.

• Computers and Concrete
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• v.8 no.4
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• pp.371-388
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• 2011

In this paper, time-continuous constitutive equations for strain rate-dependent materials are presented first, among which those for the overstress and the consistency viscoplastic models are considered. By allowing the stress states to be outside the yield surface, the overstress viscoplastic model directly defines the flow rule for viscoplastic strain rate. In comparison, a rate-dependent yield surface is defined in the consistency viscoplastic model, so that the standard Kuhn-Tucker loading/unloading condition still remains true for rate-dependent plasticity. Based on the formulation of the consistency viscoplasticity, a computational elasto-viscoplastic constitutive model is proposed for the short fiber-reinforced fresh cementitious paste for extrusion purpose. The proposed constitutive model adopts the von-Mises yield criterion, the associated flow rule and nonlinear strain rate-hardening law. It is found that the predicted flow stresses of the extrudable fresh cementitious paste agree well with experimental results. The rate-form constitutive equations are then integrated into an incremental formulation, which is implemented into a numerical framework based on ANSYS/LS-DYNA finite element code. Then, a series of upsetting and ram extrusion processes are simulated. It is found that the predicted forming load-time data are in good agreement with experimental results, suggesting that the proposed constitutive model could describe the elasto-viscoplastic behavior of the short fiber-reinforced extrudable fresh cementitious paste.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.5
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• pp.1161-1171
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• 1993

Model materials are developed to achieve similarity of flow patterns for mild steels in forming processes at high temperatures. The model materials consist of pure plasticine and one or two additives such as resin and lanolin. To verify the similarity of flow patterns between physical modeling and compression of mild steels at high temperatures, ring and compression tests have been carried out with the developed-model materials at various strain rates, temperatures and lubricants. The test results are in good agreement with the flow patterns obtained from upsetting of a mild steel at high temperatures.

• Transactions of Materials Processing
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• v.17 no.2
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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.