• Journal of the Korean Society for Precision Engineering
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• v.13 no.8
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• pp.80-87
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• 1996

The present paper will give some results of the fatigue behavior of typical axi-symmetric forward extrusion die. The extrusion process is analyzed by rigid-plastic FEM and the deformation analysis of extrusion die is conducted by elasto-plastic FEM. To approach the crack problem LEFM (Linear Elastic Fracture Mechanics) is introduced. Using special element in order to conside the sigularity of stress/ strain in the vicinity of the crack tip, stress intensity factor and the effective stress intensity factor is calculated. Applying proper fatigue crack propagation criterion such as Paris/Erdogan fatigue law and maximum principal criterion to these data, then, the angle and the direction of fatigue crack propagation is simulated. In result, it is proved that the simulated fatigue crack propagates in the zigzag path along the radial direction and fatigue life of the extrusion die is evaluated by using the computed crack growth rate.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.262-265
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• 2002

Fused deposition modelling(FDM) is a rapid prototyping(RP) process that fabricates part layer by layer by deposition of molten thermoplastic material extrude from a nozzle. RP system has many benefit. One of the benefit would be the ability to experiment wiか physical objects of my complexity in a relatively short period of time. But it has a matter of surface roughness and geometric accuracy. We study on Influence of angle of tangent line and area error on sphere surface roughness at fused deposition.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.713-716
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• 2002

The dimensional accuracy of the cold forged products is strongly dependent on the elastic behavior of the die. The elastic deformation of the die is continuously changed during the process. Therefore, it is needed to measure the deformation of die. Strain gauges are used to measure the elastic strains in the die during cold backward extrusion process. The strain gauges are attached on the die surface and embedded at the interface between the die insert and the stress ring. In order to compare the results with the FE-analysis, the rigid-plastic FE-analysis of cold backward extrusion process using DEFORM-3D has been performed, and the analysis of elastic deformation of the die has been done by using ANSYS with non-linear contact.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.05a
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• pp.81-81
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• 2004

등통로각압축(ECAP, Equal Channel Angular Pressing)공정은 다결정의 재료 덩어리를 두 채널(channel)이 일정하게 교차하는 형태의 금형에 통과시켜 단면적과 단면 형상의 큰 변화 없이 압출하는 성형법으로 다른 공정에 비해 상대적으로 낮은 압력으로 재료에 소성변형을 발생시켜 입자를 미세화 시킬 수 있으며, 기존의 분말야금에 의한 방법에 비해 상용재료를 포함한 광범위한 금속 및 합금에 적용이 용이한 점과 재료 내부에 기포가 거의 잔류하지 않는 점등의 장점을 가지고 있다.(중략)

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.485-488
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• 2005

Most metals are polycrystalline material whose deformation is dominated by the slip system. During the deformation process, orientation of slip systems is rearranged with preferred orientations, leading to deformation-induced crystallographic texture which is called deformation texture. Depending on the texture development, the property of material can be changed. The rate-independent crystal plasticity which is based on the Schmid law as a yield function causes a non-uniqueness in the choice of active slip systems. In this work, to avoid the slip system ambiguity problem, rate-independent crystal plasticity model based on the smooth yield surface with rounded-off corners is adopted. In order to simulate the polycrystalline material under plastic deformation, we employ the Taylor model of polycrystal behavior that all the grains are assumed to be subjected to the macroscopic velocity gradient. Rigid-plastic finite element program based on this rate-independent crystal plasticity is developed to predict the grain-level deformation behavior of FCC metals during metal forming processes. In the finite element calculation, one integration point is considered as a crystalline aggregate which has a number of crystals. Macroscopic behavior of material can be deduced from the behavior of aggregates. As applications, the extrusion processes are simulated and the changes of mechanical properties are predicted.

• Journal of the Korean Magnetics Society
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• v.8 no.2
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• pp.86-92
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• 1998

Homegeneous feedstock is necessary to make plastic magents with uniform magnetic properties, therefore the optrimized mixing route and the homogeneity evaluation method are demanded. In this paper, method of homogeneity evaluation and effect of homogeneity on the magnetic prperites were investigated using Sr-ferrite /EVA plastic magnets. The feedstocks with different homogeneity were prepared using batch mixer and single screw extruder. The homogeneities of feedstocks were tested by torgue sensor, capilary rheometer, and measurement of magnetic properties. Mixing torque measurement using torque sensor was an effective method to determine the critical powder loading, but it was nor suitable to suitable to determine the feedstock mixing quality. Particle alignment measurement of a plastic magent was very accurate to evaluate the homogeneity, but expensive equipments were required to make and measure the samples. Pressure measurement using capillary rheometer was a very effective and easy method with high accuracy. Homogeneous feedstock increased the particle alignment of plastic magnet. Remanet flux density and maximum energy product increased linearly and quadratically with increasing particle alignment, respectively.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.1
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• pp.49-54
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• 2010

Rotor pole for AC(alternating current) generator is manufactured through transfer warm forging die. As soon as the material is heated at the warm manufacturing process, it is transferred to the first stage for upsetting work and then to the second stage for lateral extrusion work. The processes at the lateral extrusion work such as die block, die bushing, center punch, and side punch make severe condition and abrasion which leads to shorten the die life. This causes production decrease, long maintenance time, and low level of precision. Research on the die material selection, heat process cycle improvement, electric discharge machining trouble solution, and re-construction of main parts is expected to find a method to lengthen the die life up to 40 - 50%.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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• pp.130-136
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• 2022

Reducing production costs through net-shaped cold forging is an important aspect in the automobile industry. In this study, we intend to produce a net-shaped electronic parking brake (EPB) serration gear for automobiles, using multi-stage cold forging. These serrations are then assembled to the reduction gear of an EPB actuator. The forging process of the serrations and the cold forging design were verified through finite element analysis (FEA) in order to evaluate metal flow. The forging machine was selected by checking the load using FEA. Based on the FEA results, molds were designed, and parts were made using multi-stage cold forging to produce a net-shaped serration gear.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.22-28
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• 2000

By using the finite element method, the Oyane's ductile fracture integral I was calculated from the histories of stress and strain according to every element and then the forming limit of hydroforming process could be evaluated. The fracture initiation site and the forming limit for two typical hydroforming processes, tee extrusion and bumper rail under different forming conditions are predicted in this study. For tee extrusion hydroforming process, the pressure level has significant influence on the forming limit. When the expansion area is backed by a supporter and bulged, the process would be more stable and the possibility of bursting failure is reduced. For bumper rail, the ductile fracture integral i is not only affected by the process parameters, but also by the shape of preforming blank. Due to no axial feeding on the end side of the blank, the possibility of cracking in hydroforming of the bumper rail is influenced by the friction condition more strongly than that of the tee extrusion. All the simulation results show reasonable plastic deformation, and the applications of the method could be extended to a wide range of hydroforming processes.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.684-687
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• 2002

The authors have developed two devices which cuts the spend fuel rod to an optimal size and extracts fuel pellet from the pieces of cut fuel rods. These devices are so important to reduce radioactive wastes that some advanced countries developed their own methods and devices. The authors have benchmarked from these methods and devices. For spent fuel rod cutting, the tube cutting method has been chosen. some mechanical properties of the fuel tube and pellet has been carefully considered for an optimal cutting size. For fuel pellet extraction, a mechanically extracting method has been adopted. The existing chemical method have turned out to be inappropriate because it produced large amount of radioactive wastes, in spite of its high fuel recovery characteristics. The developed method has an advantage that it can be applied to other fuel rods that have different shapes and sizes. The two devices are set up and operated in the hot cell where people can not go in, so that the devices have been designed to be controlled remotely and modulated for easy maintenance. And the performance of the devices has been tested by using simulated fuel rod. From the experimental results, the devices are supposed to be useful for reducing radioactive wastes.