• Journal of the Korean Society for Precision Engineering
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• v.2 no.2
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• pp.31-42
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• 1985

The metal flow and the strain distribution is investigated for the steady state and non-steady state bulk deformation processes by using an improved visioplasticity method which includes the effective smoothing scheme. The comparison of various smoothing schemes leads to the selection of the five- point least square smoothing method which is employed to reduce the measurement errors. As a steady state forming process experiments are carried out for axisy- mmetric forward extrusion through conical and curved dies of various area reduc- tions using Aluminum and steel billets. Axisymmetric backward extrusion is chosen for a nonsteady state forming process. In axisymmetric forward extrusion the results from visioplasticity show that the curved die of a fourth-order polynomial renders more uniform distribution of strain rates and strains. Higher reduction leads to greater strain rates at the outer side of the billet. The visioplastic observation for axisymmetric backward extrusion as a non-steady state deformation process shows the concentration of higher strain at the inner wall of the extruded product. The visioplastic results in forward extrusion are in agreement with the computed results by the finite element method. It is thus shown that the visio- plasticity combined with a smoothing technique is an effective method to determine the pattern and the distribution of strain rates and strains.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.2
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• pp.207-225
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• 1992

The study is concerned with the thermo-viscoplastic finite element analysis of axisymmetric forward hot extrusion through square dies. The problem is treated as a nonsteady state problem because the distribution of temperature and material properties are continuously changing with the punch travel. In square die extrusion, difficulties arise from the severe distortion and die interference of elements at the aperture rim of the die even with a small punch travel. And finite element computation is impossible without intermittent remeshing. Accordingly, an automatic remeshing technique is proposed by employing specially designed mesh structure near the aperture rim. The analysis of temperature distribution includes heat conduction through material interfaces, heat convection and radiation to the atmosphere and is carried out by decoupling the heat analysis from the analysis of the deformation. The extrusion load and the distributions of strain rate and temperature are computed for the given cases rendering reasonable results. Computed grid distortions are found to be in good agreement with the experimental results. It has been thus shown that the proposed method of analysis can be effectively applied to the axisymmetric hot extrusion through square dies.

• Transactions of Materials Processing
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• v.4 no.1
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• pp.69-78
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• 1995

The arbitrary Lagrangian-Eulerian(ALE) finite element analysis is applied to the axisymmetric hot extrusion through continuous dies. In order to simulate hot forming problems, an ALE scheme for temperature analysis is proposed. The computed results are compared with experimental results as with those by pure Lagrangian method. In the present study mesh control is accomplished by the use of isoparametric mapping of quadrilaterals.

• Transactions of Materials Processing
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• v.3 no.2
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• pp.156-166
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• 1994

An arbitrary Lagrangian-Eulerian (ALE) finite element method has been developed. The finite element formation is derived and implemented for rigid-viscoplastic materials. The developed computer program is applied to the analysis of axisymmetric square die extrusion, which has many difficulties with updated Lagrangian approach. The results are compared with those from updated Largrangian approach. The results are compared with those from updated Lagrangian finite element program. Updating scheme of time dependent variables and mesh control are also examined.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.8
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• pp.2005-2015
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• 1994

An analytical method based on the upper bound approach for the cup-bar axisymmetric combined extrusion is presented to determine the deformation zones as well as extrusion load and deformed geometry in the early stage. A new kiematically admissible velocity field is derived by the appropriate transformation of the original velocity field and applying the flow function approach. The derived velocity field is directly related to the boundary function for the plastically deforming zones and the parameter controlling the flow direction to the forward part or backward part. Experiments are carred out with the annealed aluminum 2024 at room temperature for the various area reductions. The workhardening effect is considered in the formulation as a function of the height ratio between the deformed billet and the orighinal billet to calculate the extrusion pressures. The theoretical predictions for the extrusion loads and deformed configuration are in good agreement with the experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.10a
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• pp.29-37
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• 1996

A ductile fracture criterion, which has already proposed, namely, ($\Delta$1/1o)f at $\Delta$$\sigma$ m=(($\Delta$1/1o)f+(-1/tan$\theta$)$\Delta$$\sigma$m(where ($\Delta$1/1o)f is fracture elongation, $\Delta$$\sigma$m is mean stress variation) was made use of to study the working limit in axisymmetric extrusion. The present investigation is concerned with the application of theory on flow and fracture to the prediction of workability of materials in axisymmetric bar extrusion, with special reference to central bursting. The influenced of die geometry and manufacturing conditions on the central bursting are predicted.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.2
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• pp.537-543
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• 1991

In this study, the strain rate effects are considered in the formulation by introducing the constitutive equation of the strain rate sensitive materials and rigid-viscoplastic finite element program is developed for axisymmtric extrusion. The effect of strain rate sensitivity on the flow characteristics and forming pressure are investigated and the experiments are carried out for extrusion with pure lead specimens. The theoretically predicted forming pressure showed reasonably good agreement with the experimental values.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.2
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• pp.144-150
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• 2000

In this paper, the formation of a corner cavity in the final stage of axisymmetric backward extrusion process is studied by means of upper bound analysis using kinematically admissible velocity. The quantitative relationships between corner cavity formation and process parameters are studied. And analytical results are compared with those of experiment to which plasticine is used. It is found that the analytical results agree well with experimental one. In addition, to restrict the formation of a corner cavity, driven container is applied to backward extrusion and the results are compared with those of FEM. The critical thickness of the bottom of the billet decreases with increase in reduction of area, and increases with decrease in friction. To prevent the formation of corner cavity, the concept of moving container was applied. Throughout this process, the occurrence of a corner cavity is delayed and forming limit area is enlarged.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.405-413
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• 2002

A process planning system for cold forging of non-axisymmetric parts of comparatively simple shape was developed in this study. Programs for the system have been written with Visual LISP in AutoCAD. Shape of the product must be drawn with the solid line and the hidden line, and with the plane and front view, as well. At the plane, the system recognizes the external shape of non-axisymmetric portions - the number of the sides of the regular polygons and the radii of circles inscribing and circumscribing the polygon. At the front view, the system cognizes the diameter of axisymmetric portions and the height of the primitive geometries such as polygon, cylinder, cone, concave, convex, etc. The system perceives that the list developed from the solid line must be formed by the operation of forward extrusion or upsetting, and that the list developed from the hidden line must be formed by the operation of backward extrusion. The system designs the intermediate geometries again by considering clearance between workpiece and die, and then finally the billet diameter, in reverse order from the finished product, on the basis of volume constancy and using the operations, the forming sequence, the number of operations and the intermediate geometries which were already designed. The design rules and knowledges for the system were extracted from the plasticity theories, handbook, relevant reference and empirical knowledge of field experts. Suitability of the process planning was analyzed using SuperForge of FVM simulation package. The results of analysis showed good formability.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.4
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• pp.452-462
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• 1985

The axisymmetric forward extrusion is analyzed by using the rigid-plastic finite element formulation. The distribution of stresses and strains as well as the deformation pattern in solid extrusion is very important for the improvement of product quality. The initial velocity field is determined by assuming the material as a Newtonian fluid through an arbitrarily shaped axisymmetric die. The workhardening effect and the friction of the die-material interface are considered in the formulation. Some reduction of area and die shapes(conical and biquadratic-curved) are chosen for computation. Experiments are carried out for steel alloy(SCM4) specimens using conical and curved dies. It is found that experimental observation is in good agreement with FEM results. The strain distribution is curved(biquadratic) dies is shown to be more uniform than in conical dies at the same reduction of area.