• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.1
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• pp.145-153
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• 1991

A numerical simulation of the nonsteady state rolling process in the plane strain condition is presented in the basis of the rigid-plastic finite element method by considering large deformation. In order to apply the large deformation theory to the numerical method for sheet rolling problems, constitutive equation relating 2nd-Piola Kirchhoff stress and Lagrangian strain which reflect geometrical nonlinearity is used. To confirm the validity of the developed algorithm, the analysis of the neutral flow region, roll separating force, torque, pressure and stress/strain distributions on the workpiece is conducted from the bite of the material until the steady state is reached. The computed results of the roll force and torque in the present finite element analysis are lower than those corresponding to small strain theory. The pressure distribution at the work piece-roll interface is found to show the typical 'friction hill' type only. The peak value in near the neutral region, however, is good agrements with the existing results. the neutral region, however, is good agrements with the existing results. The frictional force at the roll interface provide detailed information about the neutral point where the shear forces change direction. In addition, the analysis also includes the effect and influence of material condition, strip thickness, work roll diameter, as well as roll speed and lubricant on each deformation process.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.2
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• pp.507-514
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• 1991

A penalty finite element method has been developed for accurately predicting stress distributions at the tool-workpiece interfaces. The basic formulation is described, with the emphasis on the algorithm to deal with the normal stress and the frictional stress at the interface. Comparison with the experimental data and the theoretical solutions found in the literature is made for the forming processes selected.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.1
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• pp.122-129
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• 2005

On the cluster system, the parallel code of rigid-plastic FEM has been developed. The cluster system, Simforge, has 15 processors and the total memory is 4.5GBytes. In the developed parallel code, the distributed data of the column-wise partitioned stiffness are stored as the compressed row storage and the diagonal preconditioned conjugate gradient solver is applied. The analysis of block upsetting is performed with the parallel code on Simforge cluster system. In this paper, the analysis results are compared and discussed.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.3
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• pp.32-41
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• 1995

In the analysis of metal forming processes by the finite element method, there are many numerical instabilities such as element locking, hourglass mode and shear locking. These instabilities may have a bad effect upon accuracy and convergence. The present work is concerned with improvement of stability and efficiency in two-dimensional rigid-plastic finite element method using various type of elemenmts and numerical intergration schemes. As metal forming examples, upsetting and backward extrusion are taken for comparison among the methods: various element types and numerical integration schemes. Comparison is made in terms of stability and efficiency in element behavior and computational efficiency and a new scheme of adaptive directional reduced integration is introduced. As a result, the finite element computation has been stabilized from the viewpoint of computational time, convergency, and numerical instability.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.6
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• pp.725-731
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• 1985

In this study the rigid-plastic finite element method is used in order to study the deformation characteristics of solid cylinder upsetting. The effects of friction and aspect ratios on the effective strain distribution, axial stresses at the die-material interface, radial displacements, strain components, grid distortion on the meridional cross-section and gradual changes of outer profile are studied analyzed and compared with the experiments for commercially pure aluminum and .alpha.-brass. The agreement between numerical (or theoretical)and experimental results is shown to be acceptable for the engineering purpose.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.4
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• pp.125-133
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• 1998

The objective of this study is to propose a new approach for modelling of burr formation process during orthogonal cutting when the tool exits the workpiece. This approach is based on the rigid-plastic finite element method combined with the ductile fracture criterion and the element kill method. This approach is applied to orthogonal cutting process to predict the fracture location and the fracture angle as well as the cutting force. To validate this approach, orthogonal cutting tests inside SEM(scanning electron microscope) at very low speed are carried out using A16061-T6 to observe the behavior of the material during the chip and the burr formation. The results of the experiment are compared with those of the finite element simulation.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.5
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• pp.1095-1105
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• 1993

Shape rolling processes to produce H-section beams are numerically simulated by the simplified three-dimensional finite element method. The 2-dimensional finite element method, used for the generalized plane strain condition, is combined with the slab method. Computer simulation results of the 19-passes in H-section beam rolling in practice include the grid distortions, the cross-sectional area changes, the roll separating forces, and the roll torques. Also, the amount of side spread can be found during the multi-pass rolling simulations. The finite element mesh system is remeshed with I-DEAS whenever the billet distorts severely. This study would contribute to CAD/CAM of shape rolling process through the optimal roll pass schedule.

• Transactions of Materials Processing
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• v.7 no.5
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• pp.474-480
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• 1998

In the present study a domain decomposition scheme using the substructuring method is developed for the computational efficiency of the finite element analysis of metal forming processes. in order to avoid calculation of an inverse matrix during the substructuring procedure, the modified Cholesky decomposition method is implemented. As obtaining the data independence by the substructuring method the program is easily paralleized using the Parallel Virtual machine(PVM) library on a work-station cluster connected on networks. A numerical example for a simple upsetting is calculated and the speed-up ratio with respect to various number of subdomains and number of processors. The efficiency of the parallel computation is discussed by comparing the results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.246-249
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• 1998

In the present study, domain decomposition using the substructuring method is developed for the computational efficiency of the finite element analysis of metal forming processes. In order to avoid calculation of an inverse matrix during the substructuring procedure, the modified Cholesky decomposition method is implemented. As obtaining the data independence by the substructuring method, the program is easily parallelized using the Parallel Virtual Machine(PVM) library on a workstation cluster connected on networks. A numerical example for a simple upsetting is calculated and the speed-up ratio with respect to various domain decompositions and number of processors. Comparing the results, it is concluded that the improvement of performance is obtained through the proposed method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.201-206
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• 2007

In this paper, we apply a three-dimensional rigid-plastic finite element method to simulate an unsteady-state roll forming process. A typical roll forming process is investigated from the standpoint of computer simulation and its realistic analysis model is proposed. The material is considered as bulk material and discretized into hexahedral finite elements. The presented approach is applied to simulating the roll forming process of straight stringer used for aircraft structure.