Recently tube hydroforming technology has been one of the most important technology in automotive industry in the point of saving weight and high quality for collision accidents. In this paper, experimental studies for axial compression tests of hydroformed tubes are performed to investigate the collapse absorption characteristics. The collapse absorption abilities are discussed and compared for as-received, hydroformed, and press formed tubes.

One of the factors influences on microstructure of semi-solid product is forging pressure. Generally, the more forging pressure makes the more fine microstructure in semi-solid compression test. The microstructure and mechanical properties were investigated according to the forging pressure. The applied pressure is 110MPa, 140MPa and 170MPa, respectively. Heat treatment conditions also influence to the microstructure and mechanical properties of semi-solid product. T6 heat treatment was performed and the evaluation of microstructure and mechanical properties was investigated according to the aging time in T6 heat treatment.

This paper is concerned with the design of roller profiles in tube/pipe straightener with both methods of Computer Aided Design and Computer Aided Engineering. Design analysis is carried out from two point of view. The one is the research in the minimization of tube pitch which was very important factor in levelling process. In order to minimize tube pitch, profiles of the roller were calculated so that the contact region between roller and tube was maximized. The other is determination of an optimum amount of intermesh for the proper progress without a jam in levelling process. Generally the jamming trouble was casued by excessive amount of intermesh in levelling process. The optimum amount of intermesh was determined through the finite element analysis.

The mechanical joining process of a sheet metal pair has been developed in order to replace the resistance spot welding process in case that joining of mechanically unweldable materials and coated sheet metals with different thickness are needed. Form-joining or clinching, a kind of mechanical joining process, is defined as joining process of a sheet metal pair by geometric constraint imposed by plastic deformation of workpieces without any additive part. It has been reported that the joining strength by commercial form-joining apparatus is 50∼70 percent of that by resistance spot welding. Therefore, a two-step form-joining process with a secondary punch is proposed. The device is designed to improve the joining strength by increasing the geometric constraint of the deformed shape by combining a primary punch, a secondary punch and a female die. In order to verify the improved joining strength by the designed process, the tensile-shear strength, the peel-tension strength and the asymmetric peel-tension strength are compared with those by the TOX process and resistance spot welding.

Nowdays, related with vehicle weight reduction, many automotive maker are trying to develop spaceframe. If aluminum member and steel member are applied together in constructing spaceframe, there will be many advantages in aspect of inclosing strength and saving weight of automotive. In this case, joining method of aluminum and steel members has to be proposed. For this method, electomagnetic joining has many advantages compared to welding. In this paper, joining of aluminum tube and steel tube using eletomagnetic pressure was studied and strength of joint was evaluated through commission test.

A new model for heat transfer and thermal deformation analysis according to strip mm in coiling process has been proposed. Finite difference analyses for heat transfer of cold rolled coil have been carried out under various coiling tensions and strip crown using the equivalent thermal conductivity for the radial direction of cold rolled coil which is a function of strip thickness, surface characteristics and compressive pressure. The compressive pressure is calculated from a equation expressed as a function of hoop stress and coil tension considering strip mm obtained by experiment. Finite element method for thermal deformation of cold rolled coil has been performed to investigate the effects of the strip crown, the coil tension and temperature. From these analyses, it is found that the axial inhomogeneity of thermal deformation is increased as the strip crown, compressive pressure, and temperature drop in cold coiled strip increase.

In order to make a doubly curved sheet metal effectively, a sheet metal forming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation to thickness. The developed process is an unconstrained forcing process with no holder. For this study, the experimental equipment is set up with the roll set which consists of two pairs of support rolls and one center roll. In the experiments using aluminum sheets and FEM simulation, it is found that the curvature of the formed sheet metal is determined by controlling the distance between supporting rolls in pairs and the forming depth of the center roll. The FEM simulation of the forming process using the roll set along the one path shows the distributions of the curvatures in two directions along the path, and gives information about the characteristics of the proposed forming process.

Sheet or plate bending is one of the most important industrial metal forming processes. And considerable attention has been focused on gaining a better understanding of many of bending characteristics. One of defaults in bending process is the springback. In this study, the springback characteristics of tailor-welded strips in U-bending process was investigated. Furthermore, not only the relationships between the springback and the process variables such as the geometry of the tools and thickness combination of workpiece but also the heat effect which affects the springback due to welding process was experimentally considered. First, tailor-welded strips are joined by the laser welding process and consisted of two types of thickness combinations of the SCPI sheet, 0.8t${\times}$1.2t and 0.8${\times}$1.6t to investigate the effect of different thickness combination on the springback. Secondly, two different directionally welded strips, one was welded along the centerline of the strip-width and the other was along the centerline of strip-length, were adopted to compare the effects of the location of weld line on the springback. And three punch profile radii of 3, 9, and 15 m were used. Some cases of the experimental results were simulated by using a commercial FEM code, PAM-STAMP to compare the experimental results to the analytical ones.

In order to find the effect of lubricant viscosity, sheet surface roughness, tool geometry, and forming speed on the frictional characteristics in sheet metal forming, a sheet metal friction tester was designed and manufactured and friction tests of various sheets were performed. Friction test results showed that as the lubricant viscosity becomes lower, the friction coefficient is higher. When surface roughness is extreme1y low or high, the friction coefficient is high. As punch comer radius and punch speed are bigger, the value of friction coefficient is smaller. The sensitivity of friction coefficient is mainly governed by lubricant viscosity and sheet surface roughness.

A new concept of dieless sheet forming technology is proposed in this study to overcome the drawback of conventional dieless forming technology. For this purpose, dual points contact of the conventional punch system, which is a primary cause of surface defects, is replaced to single point contact using technology combined with fluid forming. It is expected that the advanced system may lead to easy displacement control of multi-punch elements, reducing surface defects, and increasing decision and forming limits. The reduced number of punch elements also saves the cost of the equipment. In addition, the new technology can be utilized for deep drawing as well as two- or three-dimensional curved surface forming, and thereby become multi-functional and multi-purpose differently from the conventional technology.

A dieless forming system which consists of hydraulic punch elements and elastomer/fluid pads, was developed for sheet metal forming. 2-D curved surface forming was carried out using open-loop, closed-loop, and repeated forming method. Closed-loop exhibited higher decision than open-loop forming. Repeated forming also showed reduced spring back and possibility of high precision.

In the ideal forming theory(1), which has been deviously developed as a direct method for optimizing forming process, material elements are required to deform following the minimum plastic work path (or the proportional true strain path). Besides the general theory(2,3), specific ideal forming theories have been developed for membrane sheet forming(4) as well as two-dimensional steady bulk forming(5-7). In this work, the ideal forming theory was successfully applied for non-steady bulk forming under the plane strain condition. Here, the shape change complying with the minimum plastic work path, was effectively described by developing a numerical code based on the characteristic method. Numerical results obtained for a specific industrial part also include the optimum pre-forming shape and its evolving shape change to the final shape as well as the boundary traction history.

Using a simple compression test, the viscosity measurement experiment is carried out with the grain-refined Al-Si alloy(A356). The measured rheological data are expressed with power-law(Ostwald-de Waele) model and using commercial package, MAGMAsoft, coefficients of Ostwald-de Waele model and Carreau-Yasuda model are calculated. To verify the viscosity data, the die is designed to be applicable to the semi-solid die casting of automotive component and filling test is carried out. The filling test and the simulation result are compared and in good agreement. Hereafter, these data are considered to be usefully allied other product in the semi-solid die casting.

A new method of optimal blank shape design using the initial nodal velocity (INOV) has been proposed for the drawings of arbitrary shaped cups. With the given information of tool shape and the final product shape, corresponding initial blank shape has been found from the motion of boundary nodes. Although the sensitivity method, the past work of Hynbo Shim and Kichan Son, has been proved to be excellent method to find optimal blank shapes, the method has a problem that a couple of deformation analysis is required at each design step and it also exhibits an abnormal behaviors in the rigid body rotation prevailing region. In the present method INOV, only a single deformation analysis per each design stage is required. Drawings of practical products as well as oil-pan have been chosen as the examples. At every case the optimal blank shapes have been obtained only after a few times of modification without predetermined deformation path. The deformed shape with predicted optimal blank almost coincides with the target shape at every case. Through the investigation the INOV is found to be very effective in the arbitrary shaped drawing process design.

A systematic investigation for process design in deep drawing is necessary for quality improvement of drawn cups. This study has been concentrated mainly on the influence of process design scheme on product qualities in cylindrical cup drawing. Three types of process design scheme were chosen in this study. That is, Case 1 is to finish drawing a cup of 50m in diameter in one stage, Case 2 and Case 3 are redrawing the drawn cups of 55, 65 mm in diameter to the final size respectively. Though experiments the maximum drawing force in two-stage cup drawing could be reduced up to 35% as compared with that of one-stage cup drawing. In addition, the Case 2 and Case 3 processes showed better product qualities than the Case 1 process when comparing distributions of thickness, hardness, dimensional accuracy.

Due to extremely large reduction of area or extrusion ratio in ordinary production of extruded profiles, anisotropy is naturally induced by large severe deformation during the extrusion process. Therefore, the anisotropic properties play a great role in the post processing of extruded profiles, such as in bending. Moreover, undesirable deformation will be involved when the deformation-induced anisotropy is ignored. In order to observe the deformation-induced anisotropy of the thin-walled product, the proposed algorithm is applied to some chosen industrial extrusion processes. In the resent work, the method for prediction of deformation-induced anisotropy employing the Barlats six-component yield potential to the rigid-plastic finite element method is proposed. The proposed algorithm is verified with the comparison to the crystallographic texture analysis, and then applied to the C-section exclusion process using a square die. The predicted anisotropy is then compared with the experimental and computational observations for validating the proposed algorithm.

Assuring required dimensional tolerance after spingback becomes the main concern of sheet-forming die designers when formability is secured through previous tryout. As a part to build a guideline to control springback in automobile frame forming, experiments are carried out to show the effects of process parameters, such as holding force, blank size, and lubrication, on corner angles of channels formed by U-bending or by square-cup drawing and trimming. The results are resented in the viewpoint of evaluating parameters.

Micromolding methods are most suitable for mass production of plastic microlens and lens array with low cost. Among the procedures related with micromolding of microlens array, fabrication of mold insect which contains micro cavity of lens shape is the most important stage. In this study, nickel mold inserts for 45 $\mu\textrm{m}$ and 95 $\mu\textrm{m}$ diameters lens way were fabricated using electroforming process. The mother for metal mold inset was made using reflow method. A micro compression molding with polymer powders was used to test the qualities of the metal mold insets. Micro lens profile and surface roughness was measured by interferometric technique and AFM, respectively. The final molded lens replicated the mother well, and had good surface quality.

As the nuclear power plant has been operated continuously and increased gradually, transportation and storage of spent fuel are seriously considered nowadays. The transportation cask which contains radioactive material needs to be inspected about structural safety. About safety verification, description of IAEA Safety Standards states that cask must withstand hypothetical accident conditions. In this paper, 9m free drop impact analysis was performed for transportation cask and impact limiter by using the finite element methods. Furthermore, we obtained the dynamic behavior of wood to as compared with safety test results, and verified the safety of transportation cask.

The 2nd forming process of flanging/hemming has recently many interest because it determines external quality of automobile. It is difficult to apply finite element simulation in flanging/hemming due to small element size which needs for expression of bending effect on the die corner and big model size of side door, back door, tank lid and like opening Parts. This paper shows the process of flanging/hemming simulation using finite element model for automotive panels. The explicit finite element program PAM-STAMP$\^$TM/ was used to simulate the flanging and hemming operations.

It is important to predict forming procedure for minimizing trial-and-error in the application of cold forging of gears. In this study, 3-dimensional simulations of cold forging processes of spur and bevel gear were carried out using finite element method to investigate the characteristics of the processes. From the simulation result it was found that incomplete teeth forming of spur gear was occurred with increase of teeth number in forging by forward extrusion. It can be reduced through division of material flows at the initial forming state using forward/backward combined extrusion.

In cold forging, the elastic behavior of the die has a direct influence on the accuracy of the forging part. And the die dimension is continuously changed during the loading, unloading, and ejecting stage. In this paper, we evaluated the elastic deflections of cold forging die during loading, unloading, and ejecting stage. Uni-axial strain gauges are used to measure elastic strain of die during each forging stage. Strain gauges are attached on the surface of die. A commercial F.E.M code, DEFORM-2D$\^$TM/ is used to predict elastic strain of die. Two method of F.E.M. analysis are used to compare with measured and calculated elastic strain. One is to regard the die as rigid body over forging cycle. And then, the die sass is analyzed by loading the die with pressure from the forging part. The other is to regard the die as elastic body from forging cycle. The elastic strain of die is calculated and the die is elastically deformed at each strop. The calculated results under the elastic die assumption are well agreed with experimental data using strain gauges.

This research is related with the development of CNC spinning machine. The purpose is to use for developing the practical parts of automobile such as dams, pulley, etc. The machine structure is made by heavy duty frame for the steel products with high strength. The hydraulic servo system is applied for giving the exactness of control. In order to improve the spinnability, the involute curves can be generated in CNC program In the future, this spinning machine is applicable to development of all the parts of industry such as electric parts, automobile parts, aerospace and the military supplies.

This paper resents a virtual forming system to simulate deep drawing process for stress-strain information by utilizing virtual system designed using Virtual Reality Modeling Language (VRML) and computer aided analysis (CAE) tool. The CAE tool to calculate stress, strain, and deformation is designed using Finite Element Method. Stress distributions and deformation profiles as well as the operation of forming machine can be simulated and visualized in the web. The developed system consists of three modules, input module, virtual forming machine module, and output module. The input nodule was designed using HTML and ASP. The input data for FEM calculation is directed to the forming machine module for calculation. The results from the forming machine module can be visualized through output module as well as the forming process simulation.

The automotive industry have made an effort to reduce the weight of vehicle structures with increased safety, while initial model of the final product does not contain any prehistoric effects in a design stave. It takes lots of time to calculate forming effects that have great influences on the energy absorption of structures. In this paper, finite element inverse analysis is adopted to calculate forming effects, such as thickness variation and effective plastic strain as well as an initial blank shape with small amount of computation time. Crash analysis can be directly performed after inverse analysis of the forming process without remeshing scheme. The direct mesh mapping method is used to calculate an initial guess from the sliding constraint surface that is extracted from the die and punch set. Analysis results show that energy absorption of structures is increased with consideration of forming effects and finite element inverse analysis is usefully applicable to calculate forming erects of vehicle structures for the crash analysis.

A unified elastic-viscoplastic ocnstitutive model based on dislocation density considerations is described. A combination of a kinetic equation, which describes the mechanical response of a material at a given microstructure in terms of dislocation glide and evolution equations for internal variables characterizing the microstructure provide the constitutive equations of the Model. Microstructural features of the material, such as the grain size, spacing between second phase particles etc., are directly implemented in the constitutive equations. The internal variables are associated with the total dislocation density in the simple version of the model. The model has a modular structure and can be adjusted to describe a particular type of metal forming processes.

This paper summarizes the results of a numerical study conducted to analyze the determination of optimum blank diameter on material flow and thread profile for Spindle Screw in external thread rolling. Initial blank diameter affect a quality of Spindle Screw in thread rolling process. Therefore, it is very important to determine the optimum blank diameter in thread rolling process. In order to determine the optimum blank diameter, this paper suggest the calculating method of initial blank diameter considering real shape of tooth. The finite element code DEFORM is applied to analyze the metal flow of tooth. then the analytical results are verified by experiment of thread rolling for Spindle Screw.

This study presents the enhancement of forgeability of SNCM522H materials. Target parts are output shaft(OP shaft) used as components of power train for automobiles. To carry out cold forging process of OP shaft by 1 pass instead of existing 2 pass process, studies in terms of process design and heat treatment were performed. To introduce the new process, Finite element Method are accomplished, and to verify the validity of proposed heat treatment cycle, several experiments(Hardness test, Observation of optical microstructures, tensile test) are carried out.

A three dimensional FEM system for supporting the design procedure of metal forming processes has been developed by integrating the FEA programs md the CAD interface modules. The system is developed to reduce the time, the extorts and the cost for establishing the successful metal forming processes for the given products. To promote practical application by engineers in medium-size enterprises who do not know much about theories of the FEA and others, various databases and intelligent interfacing modules have been developed in PC environment.

The commutator of an automotive fuel pump motorhas been produced through various processes such as forging, segmenting, and assembling. And the conventional method producing the commutator of an automotive fuel pump motor is not appropriate for saving material and cost, because it makes each segment separated one by one. Therefore a new process design is required in order to avoid the assembling process. In this study, a new process design of the commutator has been carried out to save material and manufacturing time by FE analysis. In the FE analysis, three forging processes are proposed for producing copper(ASTM C11000) commutator of an automotive fuel pump motor. And forging experiments are performed to make an unsegmented commutator in order to verify the theoretically proposed process. And then, in order to get the final product the forged commutator is passed through various postprocessing such as machining, bending, resin forming, and shearing process. From the experimental result the forging process proposed from the FE analysis is verified to be an economical method for producing the commutator for an automotive fuel pump motor.

The mechanical properties of Al 6061 excluded bar were deformed in high temperature with the variable deformation conditions and characterized by the tensile test. Three types of different strain rate were experimentally performed by using hydraulic press, crank press and hammer and two types of the nominal strain 0.5 and 0.8 were achieved. To decide optimum forging process, the relationship among the strain rate, strain and mechanical properties was explained by analyzing the microstructures of the forged and heat heated parts. The strength was deeply related with the strain rate due to the dynamic recrystallization (DRX) in hot forging, and the best forging condition was presented in Al 6061 alloy.

In this paper the stress-strain curves of bearing steels at hot working conditions are obtained by compression test with a computer controlled servo-hydraulic Gleeble 3800 testing machine and elongations and reductions of area of the bearing steels are obtained by tensile test with a computer controlled servo-hydraulic Gleeble 1500 testing machine. These tests have been focused to obtain the flow stress data and optimal hot forging conditions under various conditions of strain rates and temperatures. The strain rate sensitivity exponent and reduction of area of the materials are evaluated. Experimental results are resented for various conditions of temperatures and strain rates.

Hot forging is widely used in the manufacturing of industry machine component. The mechanical, thermal load and thermal softening which are happened by the high temperature in hot forging process. Tool life decreases considerably due to the softening of the surface layer of a tool caused by a high thermal load and long contact time between the tool and billet. Also, tool life is to a large extent limited by wear, heat crack and plastic deformation in hot forging process. These are one of the main factors affecting die accuracy and tool life. That is because hot forging process has many factors influencing tool life, and there was not accurate in-process data. In this research, life prediction of hot forging tool by wear and plastic deformation analysis considering tempering parameter has been carried out for automobile component. The new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.

Recently, the application of 3-roll mill is increasing, because of its flexibility in spread control and stand arrangements due to its compact size. But deformation characteristics and microstructural change in the process is not well known. In this study, austenite grain size (AGS) predictions were made by isothermal FE analyses and a microstructure model available in the literature. From this study, the effect of draught on the AGS characteristics was analyzed based on the divided zones of two major recrystallization behaviors.

Viscoplastic deformation and sheet forming behavior of multicomponent Zr-based bulk metallic glass alloy has been investigated. From a series of mechanical test results, basic processing maps based on Dynamic Materials Model have been constructed to establish feasible forming conditions. Stamping in laboratory scale was then performed at the various stroke speeds and temperatures using a hydraulic press. Failure in macroscopic level was examined to check the validity of constructed processing maps.

The effects of pressing temperatures on the formability and the microstructural evolution during equal channel angular pressing (ECAP) of lamellar Ti-6Al-4V alloy were investigated in this study. ECAP above isothermally 600$^{\circ}C$ was successful without producing any noticeable segments at the specimen surfaces after a single pass of pressing. After 4 passes of ECA pressing, lamellar microstructures were significantly refined revealing equiaxed grains of 0.3$\mu\textrm{m}$ in diameter consisting of high angle grain boundaries. Also these ultrafine grains were relatively stable with little grain growth when annealed up to 600$^{\circ}C$ for 1hour.

A new deformation process termed "continuouis confined sup shearing" (CCSS) has been developed for shear deformation of metallic sheets. The tools of CCSS were designed to provide a constant shear deformation of the order of 0.5 per pass while preserving the original sheet shape. In order to clarify the evolution of texture and microstructure during CCSS, strips of the aluminum alloy AA3004 were deformed by CCSS in up to three passes. FEM results indicated that CCSS provides a quite uniform shear deformation at thickness layers close to the strip center, although the deformation is not homogeneous in the die channel, in particular at the surface layers. The rolling texture of the initial sheet decreased during CCSS, and preferred orientations along two fibers developed. However, with an increasing number of CCSS passes the deformation texture did not develop futher. The evolution of annealing textures depended on the number of CCSS passes. A strong {112}<110> component in the deformation texture led to the formation of a strong {111}<112) orientation in the annealing texture. Observations by TEM and EBSD revealed the formation of very fine grains of ∼1.0$\mu\textrm{m}$ after CCSS.

The evolution of texture and microstructure during warm rolling and subsequent annealing in aluminium 3004 alloy sheet was investigated by X-ray texture measurements and microstructure observations. Warm rolling at 250$^{\circ}C$ led to the development of strong through thickness texture gradients with shear textures at the surface layer and a regular rolling texture in the center of the sheets. FEM simulations indicated that these texture gradients are caused by pronounced strain gradients throughout the sheet thickness. Upon recrystallization annealing, in the sheet center the characteristic cube-recrystallization texture developed, while in the surface layers with a pronounced shear texture continuous recrystallization took place which led to the formation of a very fine grained microstructure. It is concluded that the very complex strain history in the near-surface layers together with the resulting high work-hardening rate gave rise to the formation of the ultra-fine grains with an average size smaller than 2$\mu\textrm{m}$.

To study adiabatic shear band formation of tungsten heavy alloys, 5 prismatic specimens are loaded by high velocity impacts and treated as plane strain problems. Their volume percent of tungsten particles in WHA are 81%, 93% and 97% respectively and for the fixed 81% volume percent, small size particle model, large size particle model, undulated particle models are considered and then, the effects of particle's volume ratio, geometry and size to the formation of shear band are discussed.

The tensile properties of materials can be obtained just in accordance with conventional tensile testing methods which are described in several standards. However, the standard testing methods cannot be applicable due to the destructive testing procedure and specimen size requirement for some cases including on-service facility materials. Therefore, simple, non-destructive and advanced indentation technique was proposed. This test measures indentation load-depth curve during indentation and analyzes the mechanical properties related to deformation and fracture. In this paper, the research trend of non-destructive evaluation of tensile properties using advanced indentation system and its application fields are reviewed and discussed.

Residual stress of sheet occurs during cold rolling and it is hard to avoid and inevitable. The residual stress in the sheet cause etching curls when it suffers peroration process. The residual stress through the thickness direction in the sheet is a function of a friction coefficient, total reduction, mil size and initial sheet thickness. To estimate the residual stress and deformation due to etching curl, FEM analysis is performed. A numerical analysis is used a ANSYS 5.6 and an elastic-plastic constitutive equations. rho simulation results indicate a distribution of residual stress.