Drawing process of Al-1%Si bonding wire considering fine Si particle is analyzed in this study using FE-simulation. Al-1%Si boding wire requires electric conductivity because Al-1%Si bonding wire is used for interconnection in semiconductor device. About 1% of Si is added to Al wire for dispersion-strengthening. Distribution and shape of fine Si particle have strongly influence on the wire drawing process. In this study, therefore, the finite-element model based on the observation of wire by continuous casting is used to analyze the effect of various parameters, such as the reduction in area, the semi-die angle, the aspect ratio, the inter-particle spacing and orientation angle of the fine Si particle on wire drawing processes. The effect of each parameter on the wire drawing process is investigated from the aspect of ductility and defects of wire. From the results of the analysis, it is possible to obtain the important basic data which can be guaranteed in the fracture prevention of Al-1 %Si wire.

IC leadframe needs precision shape for good efficiency. Friction conditions also have a significant impact on blanking deformation. Therefore, studying the friction produced by the tribology between die and materials becomes necessary. In this study, in order to measure mechanical properties and frictions for leadframe materials such as Ni alloys and coppers, tensile test and straight pulling friction test are executed. In particular, the effect of clearance on the blanking characteristics depending on friction coefficient is examined by finite element simulation. From the finite element simulation, the metal flow, side pressure of punch and crack initiation are evaluated according to the leadframe materials.

A rapid tooling (RT) method fur the resin transfer molding (RTM) have been investigated. We fabricated a curved I-beam to verify the method. After creating a three-dimensional CAD model of the beam we fabricated a prototype of the model using a rapid prototyping (RP) machine. A soft mold was made using the prototype by the conventional silicone mold technique. The procedure and method of mold fabrication is described. The mold was cut into several parts to allow easier placement of the fiber preform. We conducted the resin transfer molding process and manufactured a composite beam with the mold. The preform was built by stacking up eight layers of delicately cut carbon fabrics. The fabrics were properly stitched to maintain the shape while placement. The manufactured composites beam was inspected and found well-impregnated. The fiber volume ratio of the fabricated beam was 16.85%.

The deformation behavior of copper during equal channel angular pressing(ECAP) was calculated using a three-dimensional version of a constitutive model based on the dislocation density evolution. Finite element simulations of the variation of the dislocation density and the dislocation cell size with the number of ECAP passes are reported. The calculated stress, strain and cell size are compared with the experimental data for Cu deformed by ECAP in a modified Route C regime. The results of FEM analysis were found to be in good agreement with the experiments. After a rapid initial decrease down to about 200nm in the first ECAP pass, the average cell size was found to change little with further passes. Similarly, the strength increased steeply after the first pass, but tended to saturate with further pressings. The FEM simulations also showed strain non-uniformities and the dependence of the resulting strength on the location within the workpiece.

In most of automobile body panel manufacturing, trimming process is generally performed before flanging. To find feasible trimming line is crucial in obtaining accurate edge profile after flanging. Section-based method develops blank along manually chosen section planes and find trimming line by generating loop of end points. This method suffers from inaccurate results of edge profile. On the other hand, simulation-based method can produce more accurate trimming line by iterative strategy. In this study, new fast simulation-based method to find feasible trimming line is proposed. Finite element inverse method is used to analyze the flanging process because final shape after flanging can be explicitly defined and most of strain paths are simple in flanging. In utilizing finite element inverse method, the main obstacle is the initial guess generation for general mesh. Robust initial guess generation method is developed to handle genera] mesh with very different size and undercut. The new method develops final triangular mesh incrementally onto the drawing tool surface. Also in order to remedy mesh distortion during development, energy minimization technique is utilized. Trimming line is extracted from the outer boundary after finite element inverse method simulation. This method has many advantages since trimming line can be obtained in the early design stage. The developed method is verified by shrink/stretch flange forming and successfully applied to the complex industrial applications such as door outer flanging process.

While the die casting has been mainly used to manufacture the magnesium alloy parts, the press forming is considered as an alternative to the die casting for saving the manufacturing cost and improving the structural strength of the magnesium alloy parts. Because the magnesium alloy has low formability at room temperature, forming at elevated temperatures is a necessary condition to obtain the required material flow for press forming. However, the elevated temperature forming does not always guarantee the sufficient formability under the dry friction condition because the surface damage such as scratch or wear may accelerate the material failure. In the present study, the solid-type lubricants such as PTFE, graphite and $MoS_2$ were tested for the square cup warm deep drawing using the magnesium alloy AZ31 sheet. The formability improvement by using the lubricant was examined by comparing the maximum deep drawing depth using the PTFE against no lubricant. The formability difference for the different lubricant was also examined based on the maximum deep drawing depth.

Trimming line design plays an important role in obtaining accurate edge profile after flanging. Compared to the traditional section-based method, simulation-based method can produce more accurate trimming line by considering deformation mechanics. Recently, the use of a finite element inverse method is proposed to obtain optimal trimming line. By analyzing flanging inversely from the final mesh after flanging, trimming line can be obtained from initial mesh on the drawing die surface. Initial guess generation fer finite element inverse method is obtained by developing the final mesh onto drawing tool mesh. Incremental development method is adopted to handle irregular mesh with various size and undercut. In this study, improved incremental development algorithm to handle complex shape is suggested. When developing the final mesh layer by layer, the algorithm which can define the development sequence and the position of developing nodes is thoroughly described. Flanging of front fender is analyzed to demonstrate the effectiveness of the present method. By using section-based trimming line and simulation-based trimming line, incremental finite element simulations are carried out. In comparison with experiment, it is clearly shown that the present method yields more accurate edge profile than section-based method.

The forming limit diagram of tube is required for the part design and the formability analysis of tube hydroforming. The finite element analyses of simple bulge test were done to obtain the various strain combinations on FLC. The finite element analysis results were shown that the bursting at various strain combinations could be induced by simple bulge test. The experiment oi tube bulge test was carried out according to the test condition that obtained from finite element analysis and the left hand side of forming limit diagram was built.