• Journal of the Korean Society for Precision Engineering
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• v.7 no.2
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• pp.28-38
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• 1990

The study is concerned with the theoretical and experimental investigation of axisymmetric fluid pressure-driven hydroforming of sheet metal by forming over the die cavity. The rigid-plastic finite element method is employed to calculate the stress and strain distribution. The effect of blank size and die radius is also studied in the finite element analysis. Experiments are carried out for hydroforming of cold-rolled steel sheets under various process conditions. The computational results are compared with the experimental results for the forming pressure vs. pole displacement relations and strain distributions. Comparison has shown that theoretical predictions by the finite element method are in good agreement with the experiment with the experimental observations. Thus, it is shown that the rigid-plastic finite element method is effectively used in the analysis of axisymmetric fluid pressure-driven hydroforming process.

• 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.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1996.05a
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• pp.197-205
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• 1996

A combined extrusion process studied here consists of forward and backward extrusion, and it is formed in single operation. The metal flow involved in the operation has appeared to be difficult to analyze accurately because of mixed directions of the flow. In this study, conventional two operations of a forward and a backward extrusions is transformed into one operation of mixed extrusion. A process designed by an industry expert is simulated by the rigid-plastic finite element method to investigate the metal flow and defects. In addition to the FEM simulation, experimental analysis has been carried out to confirm the design in industry, which includes material characterization, preliminary expriment, and whole experimental forming operation. The experimental results show that warm forming of extrusion is more desirable than cold working and hot forming in view of grain growth. Also two conditions of lubrication between workpiece and die has been investigated.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.1
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• pp.79-84
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• 2004

A light-guide is one of several important components of backlight unit in TFT-LCD. The manufacturing technology and optical system design of the light guide is very sensitive to quality and cost of the TFT-LCD module. In the present study a new manufacturing method which is called as direct surface forming(DSF) has been tested under various conditions. DSF is very similar to the well-known hot embossing except for partial contact between mold and substrate. The final V-groove pattern shows different shapes depend on the temperature of mold surface, contact time of mold and depth of V-groove.

• Transactions of Materials Processing
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• v.20 no.4
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• pp.291-295
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• 2011

The injector housing has two functions, namely, positioning the injector and protecting it from coolant. The conventional manufacturing process of the injector housing by machining has some drawbacks such as considerable loss of material and environmental pollution caused by excessive use of cutting oil. In this paper, precision cold forging is proposed as a new manufacturing process in order to improve these issues. A numerical study was conducted to compute the metal flow, strain, load and other process variables using DEFORM-2D, a finite element analysis(FEA) code for metal forming. Two process methods were investigated and optimal conditions were computed with the FEA code. A prototype was manufactured from the optimal process method and the metal flow and hardness were obtained from the prototype.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.1
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• pp.127-138
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• 1991

A gear forming method by cold extrusion and an analytical method with its numerical solution program based on the upper bound method were developed. In the analysis the involute curve was as a shape of die and the upper bound method was used to calculate energy dissipation rate. By this method the power requirement and optimum conditions necessary for extruding helical(spur) gear were successfully calculated. These numerical solutions are in good agreement with experimental data. In the experiment, 4-6 class helical gear of KS standard for automobile transmission was successfully manufactured.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.128-131
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• 2009

In this paper, three-dimensional finite element analysis of screw rolling process of a long shaft bolt is conducted by using a rigid-plastic finite element method based metal forming simulator AFDEX 3D. A whole sequence of cold forming processes of a long shaft bolt composed of forging and screw rolling processes is simulated to reveal the mechanism of screw formation. A mesh density control function is applied near the major plastic deformation region to achieve computational efficiency.

• Transactions of Materials Processing
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• v.19 no.4
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• pp.248-252
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• 2010

In this paper, three-dimensional finite element analysis of thread rolling process of a 12 point flange head bolt is conducted using a rigid-plastic finite element method based metal forming simulator AFDEX 3D. A whole sequence of cold forming processes of a long shaft bolt composed of four forging stages and final thread rolling process is simulated to reveal the mechanism of thread formation. A mesh density control function is applied near the major plastic deformation region to achieve computational efficiency. It has been shown both numerically and experimentally that longitudinal lengthening or shortening is negligible in thread rolling.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.6
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• pp.56-62
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• 2011

In this study, a method for the press forming of rectangular aluminium tube has been proposed. Rectangular aluminium tube has high stiff as the cold steel which can be lighter over 30% weight. It is increased every year by being recycled over 80%. Press die consists of punch, wing-die and holder for aluminium tube bending. When punch is applied with aluminium tube, holder is operated as same punch and wing-die is rotated through hinge. Stress-strain relations and springback are considered by bending angle of aluminium tube. In this study, the behaviors on tubes of square aluminium and rectangular aluminium with different thickness and area are established by the analysis of $DEFORM^{TM}$-3D program. Reducing fuel consumption is expected by using the aluminium tube deformation and it becomes the lightweight through recycling.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.6
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• pp.127-134
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• 2000

The current three-stage cold farming process to produce a flange is investigated for the purpose of improvement of manufacturing process. The main goal of this study is to obtain an appropriate process sequence, which can produce the required part with less manufacturing cost. The current process sequence is simulated using finite element method and design criteria are examined. Based on the results of simulation of the current three-stage process. a design strategy for improving the process sequence is analyzed using the thick-walled pipes. Because it has a reduced process-sequence without buckling of the workpiece or overloading of tools, the new process has distinct advantages over the conventional process. Numerical results show that the newly proposed process with selected presses is the most economical way to produce the required part.