• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.179-184
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• 1998

Semi-solid forging can be applied in industry only with enough knowledge of the effects of the forming parameters related with the process and their exact control which can be obtained by empirical or numerical methods. In the current study, the effects of process variables on semi-solid forging are discussed based on mainly numerical results. Die preheating temperature, initial solid fraction of the workpiece, and die velocity were selected as process variables, and numerical analyses using a rigid-thermoviscoplastic finite element approach that considered the release of latent heat due to phase change were carried out. In the analyses, a proposed flow stress material characterization and a solid fraction updating algorithm were employed. The obtained results from numerical analysis are discussed and are compared with some experimental observations.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.207-212
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• 1999

A computational method based on the three-dimensional finite element method is developed for the deformation analysis of roll forming process. the method approximates the process as a kinematically steady state deformation of strip. For industrial usefulness of the simulation method several rolls with arbitrary shapes in one stand can be considered. The shapes and the thickness distributions of strip after roll forming were examined by comparing computation results with experiments It is concluded that the tool is useful enough to predict the process. The overall simulation method was integrated into a sorftware package to help the industrial roll-design.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.10a
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• pp.16-29
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• 1995

A full three-dimensional thermo-coupled rigid-viscoplastic finite element method and the currently developed microstructural evolution system which includes semi-empirical mathematical equations suggested by different research groups were used together to form an integrated system of process and microstructure simulation of hot rolling. The distribution and time history of thermomechanical variables such as temperature, strain, strain rate, and time during pass and between passes were obtained FEM analysis of multipass hot rolling processes. Then distribution of metallurgical variables were calculated successfully on the basis of instantaneous thermomechanical data. For the verification of this method the evolution of microstructure in plate rolling and shape rolling was simulated and their results were compared with the data available in literature. Consequently, this approach makes it passible to describe the realistic evolution of microstructure by avoiding the use of erroneous average value and can be used in CAE of multipass hot rolling.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.159-164
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• 1997

The optimal conditions were investigated in order to manufacture the light automotive body parts using the semi-solid forging process by the finite element nalysis. Considering about macro-segregation cause to difference of relative velocity between solid phase and liquid phase, solidificational phenomenon cause to heat transfer from die and export of the latent heat, so solid fraction updating algorithm can be proposed. The rigid thermo-viscoplastic finite element analysis was carried out according to die temperature with proposed algorithm, so availability of forming part were understood. The finite element program can be used to the analysis of semi solid forging process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.207-212
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• 1997

In estimating the formability of sheet metal, the stereo vision system contributes the accuracy of strain of sheet metal, the convenience in measuring the strain of sheet metal, and the handiness in preparing the forming limit diagram by calculating the 3D values and strain of sheet metal. The algorithm has been developed so that the 3D-coordinate values of sheet metal could be calculated by image processing which is composed of camera calibration, and the stereo matching of images in two viewpoints. By comparing with experiments, the possibility and the convenience of algorithm has been verified, which could calculate the 3D-coordinate values of sheet metal automatically by using the preprocessing of the original image of sheet metal, which had the noise before adjusting the camera calibration and the stereo matching algorithm.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.165-170
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• 1997

The study presents an computer-aided analysis and its design for the forming process of $\Omega$-type bellows tube. Finite element analysis was carried out to perform the process simulation. Based on the analytic results of various conditions, the forming conditions used for angled U-type bellows tube were settled. The 3D modeling was constructed by I-DEAS and PAM-STAMP was used for process simulation. It is concluded that the spring back of formed bellows influences $\Omega$-shape and these results can be used for the process design.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.214-219
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• 1998

Analytic and experimental methods have been used for the characterization of flow behavior of semi-solid Al2024 alloy. Backward extrusion experimnet was chosen to avoid the crack on the unconstrained surface. The material constants for the flow stress by the upper bound technique that agreed with experimental results were determined. The various material constants obtained for al temperature range above the solidus temperature have been fitted and represented in the function of temperature and solid fraction. The obtained result has good agreement only in the high solid fraction.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.11
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• pp.1881-1888
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• 2003

This study show a numerical method to predict roll wear in the roll forming process. Archard's wear model was reformulated in an elemental form to predict volume of roll wear and then wear depth on the roll was calculated using the results of finite element analysis. Abrasive wear occurs at contact area in the roll forming process and the results of simulation are compared with experimental data in production line. The wear simulation approach with 3-D FEM program for roll forming process, SHAPE-RF is in good agreement with it in tendency.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.8
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• pp.1281-1286
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• 2003

A line search algorithm to increase a convergence in Newton's method is developed and applied to nonlinear finite element analysis. The algorithm is based on the slack line search theory which is an efficient algorithm to determine initial acceleration coefficient, variable backtracking algorithm proposed by some researchers, and convergence criterion based on residual norm. Also, it is capable of avoiding exceptional diverging conditions. Developed program is tested in metal forming simulation such as forging and ring rolling. Numerical result shows the validity of the algorithm for a highly nonlinear system .

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.4
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• pp.524-530
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• 2003

This paper presents a new model on deformation characteristics of cylindrical tubes under pure bending. The model is based on the upper bound method that minimizes total strain energy of a system. It does not assume inextensibility condition. Geometric relations and displacement fields are derived by analysis of deformation behaviors of elastic tubes. Simulations are calculated using numerical optimization and integration techniques. The results give information about cross-sectional deformation of cylindrical tubes. Simulation results are compared with available data in literatures, which show that this method predicts deformation characteristics of tube bending process.