Rapidly developing IT technologies in recent years have raised the demands for high-precision optical lenses used for sensors, digital cameras, cell phones and optical storage media. Many techniques are required to manufacturing high-precision optical lenses, including multi-beam sensing lenses investigated in the current study. In the case of injection molding for thick lenses, a shrinkage phenomenon often occurs during the process. This shrinkage is known to be the main reason for the lower optical quality of the lenses. In the present work, a CAE analysis was conducted simultaneously with experiments to understand and minimize this phenomenon. In particular, the sectional area of a gate was varied in order to understand the effects of packing and cooling processes on the final shrinkage pattern. As a result of this study, it was demonstrated that a dramatic reduction of the shrinkage could be obtained by increasing the width of the gate.

This paper presents methods for analyzing the extent of cylindrical-shaped void closure. In addition, a quantitative relationship between change in void fraction and height reduction ratio of a compressed specimen is proposed. The height reduction ratio, number of deformation steps and billet rotation were chosen as key process parameters influencing the void closing behavior, namely, the changes in void shape and size during hot open die forging of a large ingot. The extent of void closure was analyzed from microscopic observations and estimated from tensile test results. The tensile strengths of specimens with closed voids and those without were compared for various reduction ratios in height. The results confirmed that void closure occurs at reduction ratios greater than 30 %. The void closing behavior could be expressed as a hyperbolic tangent function of reduction ratio in height, number of paths, and billet rotation. The knowledge presented in this paper could be helpful for optimizing deformation paths in open die forging processes.

Variation of contact pressure causes change of friction coefficient, which in turn changes stress distribution in the sheet being formed and final springback. In the present study, U-draw bending experiments were carried out under constant blank holding force(BHF) and different blank sizes, and finite element analysis was conducted with and without considering contact pressure effect on friction. When the BHF was sufficiently high, the degree of springback was different between constant blank holding pressure condition and that with varying blank holding pressure. Finite element analysis considering the influence of contact pressure effect on friction could explain the occurrence of springback.

Shape memory alloys(SMAs) exhibit pseudoelastic behavior, characterized by the recovery of an original shape even after severe deformation, during loading and unloading within appropriate temperature regimes. The distinctive mechanical behavior is associated with stress-induced transformation of austenite to martensite during loading and reverse transformation to austenite upon unloading. To develop a material model for SMAs, it is imperative to consider the difference in moduli of active phases. For example, the Young’s modulus of the martensite is one-third to one half of that of the austenite. The model proposed herein is a modification of the one proposed recently by Ho[17]. The prediction of the behavior of SMAs during unloading before the onset of reverse transformation was improved by introducing a new internal state variable incorporating the variation of the elastic modulus.

A beryllium copper alloy(C1720) sheet was stretch-drawn using different processes. A hemispherical punch was first used and the forming behavior was examined. Then, cylindrical cups with a hemispherical head were produced by either one-step drawing or two-step forming(sequential stretch forming-drawing). The one-step drawing showed the better formability than two-step forming. However, the two-step forming was the superior process in terms of attaining shape accuracy.

For the purpose of improving crashworthiness qualities and maximizing weight saving efficiency, TWB's(tailor welded blanks) of quench-hardenable boron steel sheet formed by hot stamping processes has been used for automotive BIW (body in white) applications. In this work, the flow behaviors of TWB of quench-hardenable boron steel sheet were investigated in uniaxial tension tests at elevated temperature. TWB's having a uniform thickness of 1.4mm were fabricated by laser welding. Specimens with two weld line directions were used to test the mechanical property and reliability of the weld zone. After heating at $950^{\circ}C$ for 5min, the specimens were subjected to tension test at 650, 700 and $800^{\circ}C$ with a strain rate of 0.01 /s and at $700^{\circ}C$ with strain rates of 0.01, 0.1 and 1/s. The ultimate strength of the weld zones was higher than that of the base materials at 650 and $700^{\circ}C$, but was similar to the base metal at $800^{\circ}C$. Fracture occurred at the base material at 650 and $700^{\circ}C$, but at the weld zone at $800^{\circ}C$.

본 연구를 통하여 비이차 비등방 항복 응력 포텐셜들의 근접 짝되는 변형률 속도 포텐셜들에 대해서 정리하고 Yld2000-2d의 근접 짝되는 Srp2003-2d에 대해서 상세 설명하였다. 제안된 비이차 비등방 변형률 속도 포텐셜 Srp2003-2d 식 형태가 소개 되었고, 볼록성이 증명되었다. 아울러 이방성 상수를 구하는 방법이 제시되었다. Srp2003-2d의 소성 거동을 살펴보기 위하여 자동차 용 알루미늄 합금 판재 AA6022-T4와 항공재료용 알루미늄 합금 AA2090-T3에 응용되었다. Srp2003-2d는 항복 응력 포텐셜 Yld2000-2d와 거의 흡사한 짝됨을 보여 주었으며, 알루미늄 판재의 비등방성을 적절히 묘사하였다. Srp2003-2d는 알루미늄 판재의 성형 공정의 모사를 위하여 이상 공정 이론을 비롯한 강소성체 재료에 대한 정식화에 적절히 응용될 수 있을 것이다.

During stamping processes, the air trapped between sheet metal and the die cavity can be highly compressed and ultimately reduce the shape accuracy of formed panels. To prevent this problem, vent holes and passages are sometimes drilled into the based on expert experience and know-how. CAE can be also used for analyzing the air behavior in die cavity during stamping process, incorporating both elasto-plastic behavior of sheet metal and the fluid dynamic behavior of air. This study presents sheet metal forming simulation combined simultaneously with simulation of air behavior in the die cavity. There are three approaches in modeling of air behavior. One is a simple assumption of the bulk modulus having a constant pressure depending on volume change. The next is the use of the ideal gas law having uniform pressure and temperature in air domain. The third is FPM (Finite point method) having non-uniform pressure in air domain. This approach enables direct coupling of mechanical behavior of solid sheet metal and the fluid behavior of air in sheet metal forming simulation, and its result provides the first-hand idea for the location, size and number of the vent holes. In this study, commercial software, PAM-$STAMP^{TM}$ and PAM-$SAFE^{TM}$, were used.