In this paper, finite element analysis of an automatic five-stage precision cold forging process of a yoke, a steering part of a passenger's car, is conducted with emphasis on spring back analysis at the yoke-forming stage and its experimental verification is subsequently made. An elastoplastic finite element method with MINI-element technique employed for the analysis of the entire process is explained. There is emphasis that the thin film of material formed between the punch and die in the stage may result to some errors especially in elastoplastic finite element analysis of spring back due to frequent remeshing. The numerical robustness of the spring back analysis in regards to remeshing is hence shown first through investigation into its effect on the predicted spring back. Experimental measurement of displacement due to spring back is carried out for comparison with the predicted results, and they are in a qualitative agreement with each other.

Hypereutectic Al-Si alloys have been widely utilized for wear-resistant components in the automotive industry. In order to expand the application of Hypereutectic Al-Si alloys, the addition of alloying elements forming a stable precipitate at high temperature is required. Thermally stable inter metallic compounds can be formed through the addition of transition elements such as Fe, Ni to Al alloys. However, the amount of transition element to be added to Al alloys is limited due to their low solid solubility. Also, hypereutectic Al-Si-Fe alloys form coarse primary Si phases and needle-shaped intermetallic compounds during solidification in the general casting processes. In this study, the effects of the destruction of Intermetallic compound and Si phase are investigated via hot extrusion. Both the microstructure and mechanical properties are discussed under different extrusion conditions.

Electrically assisted (EA) springback reduction of grade 2 titanium alloys is demonstrated through u-bending experiments. A single pulse of electric current having a short duration of less than 0.5 sec is applied to a specimen during u-bending. The effect of the electric current condition on the resultant springback is then evaluated. The experimental result shows that the springback of the selected grade 2 titanium alloy could almost be eliminated through application of electric current with a duration less than 0.5 sec prior to unloading. Lastly, an exemplary industrial application of EA springback control is presented.

Electromagnetic impulse welding (EMIW) is a type of solid state welding using the Lorentz force generated by interaction between the magnetic field of the coil and the current induced in the workpiece. Although many experimental studies have been investigated on the expansion and compression welding of tube using the EMIW process, studies on the EMIW process of lap joint between flat sheets are uncommon. Since the magnetic field enveloped inside the tube can be controlled with ease, the electromagnetic technique has been widely used for tube welding. Conversely, it is difficult to control the magnetic field in the flat sheet welding so as to obtain the required welding velocity. The current study analyzed the effects of coil shape on the impulse velocity for suitable flat one-turn coil for the EMIW of the flat sheets. The finite element (FE) multi-physics simulation involving magnetic and structural field of EMIW were conducted with the commercial software LS-DYNA to evaluate the several shape variables, viz., influence of various widths, thicknesses, gaps and standoff distances of the flat one-turn coil on the impulse velocity. To obtain maximum impulse velocity, the flat one-turn coil was designed based on the FE simulation results. The experiments were performed using an aluminum alloy 1050 sheets of 1.0mm thickness using the designed flat one-turn coil. Through the microscopic interfacial analysis of the welded specimens, the interfacial connectivity was observed to have no defects. In addition, the single lap joint tests were performed to evaluate the welding strength, and a fracture occurred in the base material. As a result, a flat one-turn coil was successfully designed to guarantee welding with bond strength equal to or greater than the base material strength.

The objective of this study is to analyze the mechanical splicing characteristic of the threaded bar according to the contact conditions of the transverse rib. In order to consider the contact conditions of the rib, selection of the main variables including the gap of the core diameter ($l_c$), rib angle (${\theta}$), and the number of contacts ($C_N$) of transverse rib was done. So as to analyze the splicing characteristic of the D51 threaded bar, a finite element (FE) simulation of the tensile test was conducted using the designed D51 threaded bar and coupler. Through FE simulation results, it was verified that the mechanical slicing characteristics varied based on the main design variables ($l_c$, ${\theta}$, and $C_N$). It was further confirmed that it was important to determine the $C_N$ in consideration of $l_c$. Additionally, the tensile test results of the D25 and D51 threaded bar combined with the couplers were similar to FE simulation results. Furthermore, to quantitatively evaluate FE simulation and test results, the calculation equation for the contacted projection area ratio (R) of the transverse rib was proposed. To secure a mechanical splicing joint of the threaded bar, it was established that the R calculated using the proposed equation had to be greater or equal to 40%.

The hole expansion tests using conical punch, flat punch or hemispherical punch are widely used for stretch flangeability verification of HSS. In this study, we investigate the strain distribution on the shear edges of the hole expansion test using grid marking and a projector. A small crack at the edge is distributed, resulting in a large gap between the HER and the crack strain. The strain distribution at the edges is irregular due to anisotropy of sheet metal. While an edge perpendicular to the rolling direction indicate a lower strain level compared to an edge parallel to the rolling direction, edge cracks occur at the edge perpendicular to the rolling direction. To predict the manifestation of edge cracks in FE analysis, the result of the hole expansion test with a crack strain measurement may well be a better tool than FLD. In this case, the level of strain and the direction of the edge relative to the rolling direction should be well considered.

Electromagnetic forming (EMF) simulations consider 3-dimensionally coupled electromagnetic-mechanical phenomenon using LS-DYNA, therefore the calculation cost is normally expensive. In this study, a sensitivity analysis in regard to the simulation variables affecting the calculation time was carried out. The EMF experiments were conducted to form an elliptically protruding shape on a high-strength steel sheet, and it was predicted using LS-DYNA simulation. In this particular EMF simulation case, the effect of several simulation variables, viz., element size, contact condition, EM-time step interval, and re-calculation number of the EM matrices, on the shape of elliptical protrusion and the total calculation time was analyzed. As a result, reasonable values of the simulation variables between the simulation precision and calculation time were proposed, and the EMF experiments with respect to the charging voltages were successfully predicted.