Large load is required in forging of large-scale components which becomes a critical restriction in practice. In the present study, two methods of incremental forging were investigated for the purpose of reducing the load required for forging of large and thick plates. The forging was applied primarily to obtain fine grains by imposing large amount of plastic deformation to the plates. One was to use nine strokes with a flat die and the other was to use three strokes with a curved die. The die moves vertically in the former while it moves vertically as well as rolls horizontally in the latter. Deformation of the slab in each case was analyzed by rigid-plastic finite element method and as a result, variations of load and slab holding force, and distributions of effective strain and thickness were predicted.

The study is concerned with shape correction of stamped product using the laser irradiation. As a fundamental study, laser irradiation process has been analyzed through the thermo-mechanical FE analysis. For the purpose of validation, laser scanning experiment has been carried out also. Since the deformation mechanism involved in the laser scanning is extremely complicated due to the highly temperature dependent material properties, the determination of laser scanning pattern is not easy for the application of real stamped parts. A simplified method for the application of springback correction has been suggested with the thermo-mechanical FE analysis.

The effect of blank holding force on thickness variation in simultaneous sheet forming with rectangular shape and circular has been demonstrated. Because has investigated an effect on formability of magnesium sheet, in this paper, the effect of punch radius on formability have been thinning, various crack phenomena and forming velocity. By simultaneously forming process with circular and rectangular shape, the data of simultaneously forming process with circular and rectangular shape will used to a part development such as notebook computer case, cell phone and bipolar plate of fuel cell.

The cowl cross bar of an automobile is a frame component that is installed inside the cockpit module to provide a guide surface, to which functional components for electricity and air condition are attached. In the recent years, the geometries of cowl cross bars are getting more complex in order to meet the demands of a wide variety of embedded functional components and the reduced weight of frame parts with enhanced mechanical and noise/vibration characteristics. There for, welding processes between tubes with different diameters are widely conducted while the welded parts are experiencing various problems such as undermined appearance, low production efficiency and poor mechanical characteristics. Therefore, this paper seeks to develop an one-piece forming process which eliminate welding process for the cowl cross bar by applying the tube drawing process. However, it was predicted that a conventional tube drawing can not be applied directly to the current part since the area reduction ratio of the drawing process reaches 51.7% which exceeds the general limiting value. Therefore, in this study, a combined drawing process which adds a compressive force to a tensile force of the conventional drawing process was proposed and 2-stage drawing process was designed by using CAE analyses. In addition, drawing tryouts were carried out by using the manufactured combined drawing machine in order to verify the designed process.

This study aimed to elucidate the deformation mechanism during low-temperature superplasticity of fine-grained Ti-6Al-2Sn-4Zr-2Mo-0.1Si alloy in the context of constitutive equation. For this purpose, initial coarse equiaxed microstructure was refined to $2.2{\mu}m$ via dynamic globularization. Globularized microstructure exhibited large superplastic elongations(434-826%) at temperatures of $650-750^{\circ}C$ and strain rate of $10^{-4}s^{-1}$. It was found that the main deformation mechanism of fine-grained material was grain boundary sliding accommodated by dislocation motion with both stress exponent (n) and grain size exponent (p) values of 2. When the alpha grain size, not sub-grain size, was considered to be an effective grain size, the apparent activation energy for low-temperature superplasticity of the present alloy(169kJ/mol) was closed to that of Ti-6Al-4V alloy(160kJ/mol).

In the multi-pass shape drawing process, the pass schedule that includes the determination of reduction ratio and intermediate die shape is very important. This study used the equal reduction, equal load, and electric field analysis method for pass schedule of the multi-pass shape drawing. The reduction ratio was calculated by the equal reduction and equal load method. And the intermediate die shape was determined by the result of the electric field analysis and the calculated reduction ratio. The proposed pass schedule method was applied to a shape drawing for producing cross roller guide. Finally, FE-analysis and shape drawing experiment were performed to verify the effectiveness of the proposed method.

Flexible forming process for sheet material using reconfigurable die is introduced based on numerical simulation. In general, this flexible forming process using the reconfigurable die has been utilized for manufacturing of curved thick plates used for hull structures, architectural structures and so on. In this study, numerical simulation of sheet metal forming process is carried out by using flexible dies model instead of conventional matched die set. The numerical simulation and experimental verification for sheet metal forming process using a flexible forming machine that is more suitable for thick plate forming process are carried out to confirm the appropriateness of the simulation process. As an elastic cushion, urethane pads are utilized using hyperelastic material model in the simulation for smoothing the forming surface which is discrete due to characteristics of the flexile die. In the flexible forming process for sheet metal, effect of a blank holder is also investigated according to blank holding methods. Formability in view of occurrence of dimples is compared with regard to the various punch sizes. Consequently, it is confirmed that the flexible forming for sheet material using urethane pad has enough capability and feasibility for manufacturing of smoothly curved surface instead of conventional die forming method.

This paper is concerned with the analysis on the surface stress profiles of perfectly plastic material in backward extrusion process. Due to heavy surface expansion appeared usually in the backward extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the analyses have focused to reveal the surface conditions at the contact boundary for various punch shapes in terms of surface expansion, contact pressure, and relative movement between punch and workpiece which consists of sliding velocity and distance, respectively. Punch geometries adopted in the analysis include concave, hemispherical, pointed and ICFG recommended shapes. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward extrusion process under different punch geometries. The simulation results are summarized in terms of surface expansion, contact pressure, sliding velocity and sliding distance at different reduction in height, deformation patterns, and load-stroke relationship, respectively.