• Journal of the Korean Society for Precision Engineering
• /
• v.24 no.4 s.193
• /
• pp.115-122
• /
• 2007

Recently, remarkable progress has been made in both technology and production of optical elements including aspheric lens. Especially, requirements for machining glass materials have been increasing in terms of limitation on using environment, flexibility of material selection and surface accuracy. In the past, precision optical glass lenses were produced through multiple processes such as grinding and polishing, but mass production of aspheric lenses requiring high accuracy and having complex profile was rather difficult. In such a background, the high-precision optical GMP process was developed with an eye to mass production of precision optical glass parts by molding press. This GMP process can produce with precision and good repeatability special form lenses such as camera, video camera, aspheric lens for laser pickup, $f-\theta$ lens for laser printer and prism, and me glass parts including diffraction grating and V-grooved base. GMP process consist a succession of heating, forming, and cooling stage. In this study, as a fundamental study to develop molds for GMP used in fabrication of glass lens, we conducted a glass lens forming simulation. In prior to, to determine flow characteristics and coefficient of friction, a compression test and a compression farming simulation for PBK40, which is a material of glass lens, were conducted. Finally, using flow stress functions and coefficient of friction, a glass lens forming simulation was conducted.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.10b
• /
• pp.36-39
• /
• 2003

Due to the strength and biocompatibility requirement, the stainless steel SUS 316L is widely used for trauma internal fixation device. SUS 316L can be hardened and strengthened only by cold work. In this work, the material compression test is performed both in laboratory and computer simulation by a FEM analysis software DEFORM to correlate the hardness to strain. This data is then used for preform design and predict the hardness of the finish bone plate forging. Finally, we compared the hardness between the actual forging and computer analysis results. Although the predicted hardness from computer simulation. is 55HV higher than the final forging sample, we can get good compatibility on the hardening tendency of cold forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.539-542
• /
• 2008

Recently, GMP(Glass Molding Press) process is mainly used to produce aspheric glass lenses. Because glass lens is heated at high temperature above Ty (yielding point) for forming glass, the quality of aspheric glass lens is deteriorated by residual stresses which are generated in a aspheric glass lens after forming. Before this study, as a fundamental study to develop forming conditions for progressive GMP process, compression, strain relaxation and thermal conductivity tests were carried out to obtain the visco-rigid plastic, the visco-elastic and thermal properties of K-PBK40 which is newly developed and applied for precision molding glass material, In this study, using the experimental results we obtained, a glass lens forming simulation in progressive GMP process was carried out and we could forecast the shape of deformed glass lenses and residual stresses contribution in the structure of deformed glass lenses after forming.

• Design & Manufacturing
• /
• v.18 no.2
• /
• pp.29-34
• /
• 2024

This study intends to reduce forming load by adding die rotation to flange-upsetting process. Materials arc formed by the compression and rotational torque which are accrued from rotation of the lower die accompanied by axial compression of the punch. For the theoretic analysis of flange-upsetting process using rotation die, slab method was used. Furthermore, for the verification of the theoretic analysis results, FEM simulation using DEFORM 3D a commercial software was done, and through the model material experiment using Prasticine, the results were compared and reviewed. Flange-upsetting process using rotation die shows reduced forming load compared with process without die rotation and demonstrates uniform distribution of strain. And as for the effect of the reduction of forming load, the less the aspect ratio(h₀/d₀) and the greater friction coefficient, the greater effect is. With increase in die rotation velocity, the effect of forming load reduction also increases little by little, but its effect on forming load reduction is very negligible compared with other forming parameters. Theoretic analysis results and simulation results coincided pretty well. The flange-upsetting process using die rotation are evaluated as useful process that can produce reduction of forming load and uniform strain.

• Transactions of Materials Processing
• /
• v.4 no.3
• /
• pp.204-213
• /
• 1995

A finite element program is developed to analyze the flow phenomena in SMC compression molding as a viscoplastic model. The calculation of temperature distribution is also carried out by uncoupling the thermal analysis from the flow analysis. SMC molding processes with a flat plate substructure and the one with a T-shaped rib are considered in numerical simulation. The numerical results provide deformed shapes, temperature distribution in a SMC charge, and the forming load. The simulation of compression molding of a flat plate with a T-shaped rib requires a remeshing technique for the whole process.

• Composites Research
• /
• v.31 no.6
• /
• pp.421-428
• /
• 2018

In order to optimize the prepreg compression molding (PCM) process, the forming simulation is required to cope with any problems that may be raised during the process. For the improvement of simulation accuracy, the input data of material property should be measured accurately. However, most studies assume that the compressive properties of the prepreg are identical to the tensile properties without quantifying them separately. Therefore, in this study, the in - plane compressive properties of the prepreg are presented to improve the accuracy of the forming simulation. As a result, the compressive modulus of the fibers was measured to be about $10^{-2}$ times lower than the tensile modulus. Also we designed a square-cup mold with a tilting angle of $110^{\circ}$ to simulate the prepreg formability during the high temperature compression mold process. Shear angles were measured at each corner, which were compared with the simulation results. It was observed that the simulation results using the accurate compressive properties of the prepreg showed a similar trend with the experimental results. It was confirmed that the measured data of the in-plane compression property improved the accuracy of the forming simulation results.

• Transactions of Materials Processing
• /
• v.15 no.5 s.86
• /
• pp.395-401
• /
• 2006

It is reported that semi-solid forming process takes many advantages over the conventional forming process, such as a long die life, good mechanical properties and energy saves. It is important to predict the deformation behavior for optimization of the forging process with semi-solid materials and to control liquid segregation for mechanical properties of materials. But rheology material has thixotropic, pseudo-plastic and shear-thinning characteristics. So, it is difficult for a numerical simulation of the rheology process to be performed because complicated processes such as the filling to include the state of the free surface and solidification in the phase transformation must be considered. General plastic or fluid dynamic analysis is not suitable for the analysis of the rheology material behavior. Recently, molecular dynamics is used for the behavior analysis of the rheology material and turned out to be suitable among several methods. In this study, molecular dynamics simulation was performed for the control of liquid segregation, forming velocity, and viscosity in compression experiment as a part of study on the analysis of rheology forming process.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.10a
• /
• pp.649-652
• /
• 2005

It is reported that semi-solid forming process takes many advantages over the conventional forming process, such as long die lift, good mechanical properties and energy saves. Rheology material has a thixotropic, pseudo-plastic and shear-thinning characteristic. Therefore, general plastic or fluid dynamic analysis is not suitable for the behavior of rheology material. So it is difficult for a numerical simulation of the rheology process to be performed because complicated processes such as the filling to include the state of the free surface and solidification in the phase transformation must be considered. Moreover, it is important to predict the deformation behavior for optimization of net shape forging process with semi-solid materials and to control liquid segregation for mechanical properties of materials. In this study, so, molecular dynamics simulation was performed for the control of liquid segregation in compression experiment as a part of study on analysis of rheology forming process.

• Design & Manufacturing
• /
• v.17 no.1
• /
• pp.48-55
• /
• 2023

In this study, on the structure simulation for manufacturing a high strength/light weight 48V battery housing for a mild hybrid vehicle was conducted. Compression analysis was performed in accordance with the international safety standards(ECE R100) for existing battery housings. The effect of plastic materials on compressive strength was analyzed. Three models of truss, honeycomb and grid rib for the battery housing were designed and the strength characteristics of the proposed models were analyzed through nonlinear buckling analysis. The effects of the previous existing rib, double-sided grid rib, double-sided honeycomb rib and double-sided grid rib with a subtractive draft for the upper cover on the compressive strength in each axial direction were examined. It was confirmed that the truss rib reinforcement of the battery housing was very effective compared to the existing model and it was also confirmed that the rib of the upper cover had no significant effect. In the results of individual 3-axis compression analysis, the compression load in the lateral long axis direction was the least and this result was found to be very important to achieve the overall goal in designing the battery housing. To reduce the weight of the presented battery housing model, the cell molding method was applied. It was confirmed that it was very effective in reducing injection pressure, clamping force and weight.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2007.05a
• /
• pp.170-175
• /
• 2007

The finite volume method for forging simulation is examined to reveal its possibility as well as its problem in this paper. For this study, the finite volume method based MSC/SuperForge and the finite element method based AFDEX are employed. The simulated results of the homogeneous compression obtained by the two softwares are compared to indicate the problems of the finite volume method while several application examples are given to show the possibility of the finite volume method for simulation of upsetter forging processes. It is shown that the finite volume method can not predict the exact solution of the homogeneous compression especially in terms of forming load and deformed shape but that it is helpful to simulate very complex forging processes which can hardly be simulated by the conventional finite element method.