• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.10a
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• pp.195-199
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• 1993

In the analysis of metal forming processes by the finite element method, there are many numerical instabilities such as element locking, hourglass mode, 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 elements and numerical integration 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. As a result, it has been shown that the finite element computation is stabilized from the viewpoint of computational time, convergency, and numerical instability.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.9
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• pp.126-136
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• 1995

Copper magnetron anode of a microsave-over consists of an cylindrical outer-tube and various inner-vanes. The magnetron anode is produced by the complex processes; vane blanking, pipe cutting and silver-alloy brazing of vanes. Recently, the backward extrusion process for forming vanes has been developed to avoid the complex procedures. The developed process is analyzed by using upper-bound elemental technique (UBET). In the UBET analysis, the upper-bound load, the configuration and the vane-height of final extruded product are determined by minimizing the roral power consumption with repect to chosen parameters. To verify theoretical analysis, experiments have been carried out with pure plasticine billets at room temperature, using different web-thickness and number of vanes. The theoretical predictions both for forming load and vane-height are in reasonable agreement with the experimental results.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1361-1366
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• 2007

Forging for spring cup of engine valve was investigated in this study. New method is needed to reduce cost and development lead time required to fix forming process of new product, that eventually can provide die, metal flow and forming loads with high confidence level. FEM could provide required detail information that could reduce trial error in advance before the actual production. By using the rigid-plastic finite element simulation, possibilities of improving former research were explored. Results generated by FEM could foresee expected material deformation in advance and made possible new forming process successfully.

• 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.18 no.9
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• pp.2234-2244
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• 1994

A process sequence of multi-operation cold forging for actual application in industry is designed with the rigid-plastic finite element method to form a constant velocity joint housing(CVJ housing). The material flow during the CVJ housing forming is axisymmetric until the final forging process for forming of ball grooves. This study treats the deformation as an axisymmetric case. The main objective of the process sequence design is to obtain preforms which satisfy the design criteria of near-net-shape product requiring less machining after forming. The process sequence design also investigates velocity distributions, effective strain distributions and forging loads, which are useful information in the real process design.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.1
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• pp.24-30
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• 2009

In this paper, the effect of heat treatment on forgeability is investigated and an improved heat treatment cycle is proposed for the bearing steel, SUJ2. An application example of a bearing inner race cold forging, which has small cracks in the bottom after backward extrusion and piercing, is found from a cold forging industry. The process is evaluated by finite element analysis and several heat treatment cycles are examined in order to propose an improved heat treatment cycle. The effect of heat treatment on material hardness and tool life, dimensional accuracy and forming load is revealed through experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.98-101
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• 1999

The plastic instable flow phenomenon happens in practical forming process I. e. upsetting backward extrusion piercing indentation. And also it is difficult to control precisely the shape and dimensions of forming process. It is found that instabilities of the process are mainly connected with imperfection in the lubrication billet eccentricity inclined punch alignment. In view of the direct relationship between instable material flow and quality defects of the products and it is for better control of forming operation we should necessarily find out their phenomena. In this study we used the friction disturbance due to inclined punch angle and introduced the method considering kinematic hardening effect Analysis of upset forging is carried out using the rigid plastic FEM and slab method with eccentricity.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.155-158
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• 2000

Flow defect of a piston-pin for automobile parts is investigated in this study. In cold forging of piston-pin Lapping defect a kind of flow defect appears by the dead metal zone. This appearance evidently happens in products with a thin piercing thickness for the dimension accuracy and the decrease of material loss. The best method that can prevent flow defect is removing dead metal zone. The finite element simulations are applied to analyze the flow defect. This study proposed processes for preventing flow defect by removing dead metal zone. Then the results are compared with the experiments for verification. These FE simulation results are in good agreement with the experimental ones.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.204-208
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• 1995

Copper magnetron anode of a microwave-oven consists of an cylindrical outer-tube and various inner-vanes. The magnetron anode is produced by the complex process ; vane blanking, pipe cutting and sliver-alloy brazing of vanes. Recently, the backward extrusion process for forming vanes has been developed to avoid the complex procedures. The developed process is analyzed by using upper-bound elemental technique(UBET). In the UBET analysis, the upper-bound load, the configuration and the vane-height of final extruded product are determined by minimizing the total power consumption with respect to chosen parameters. To verify theoretical analysis, experiments have been carried out with pure plasticine billets at room temperature, using different web-thickness and number of vanes. The theoretical predictions both for forming load and vane-height are in reasonable agreement with the experimental results.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.5
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• pp.653-660
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• 1986

Two uppor bound solutions, by the force balance method and by a kinematically admissible velocity field, are compared for the metal forming problems in plane strain. It is concluded that these two approaches always give identical results when the geometrical configurations of the deformation model reman the same. By detailed derivations for plastic bending of a notched bar, closed die forging, compression of a rectangular block, machining with a restricted contact tool and plane strain backward extrusion, the identity of both approaches is verified.