• Transactions of Materials Processing
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• v.13 no.6 s.70
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• pp.540-545
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• 2004

Ever since the ideal forming theory has been developed for process design purposes, application has been limited to sheet forming and, fur bulk forming, to two-dimensional steady flow. Here, application for the non-steady case was performed under the plane-strain condition based on the theory previously developed. In the ideal flow, material elements deform following the minimum plastic work path (or mostly proportional true strain path) so that the ideal plane-stram flow can be effectively described using the two-dimensional orthogonal convective coordinate system. Besides kinematics, fur a prescribed final part shape, schemes to optimize a preform shape out of a class of initial configurations and also to define the evolution of shapes and boundary tractions were developed. Discussions include the two problematic issues on internal tractions and the non-monotonous straining. For demonstration purposes, numerical calculations were made for a bulk part under forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.219-222
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• 2005

The temperature difference between die and workpiece has frequently caused various surface defects. The non-homogeneous temperature distribution of forged part should be analyzed to prevent the generation of various defects related with the temperature. The surface temperatures were mainly affected by the coefficient of thermal contact conductance. The precise coefficient is necessary to predict accurately the temperature changes of die and workpiece. The experiment is preformed to measure the temperature distribution of die and workpiece in closed die upsetting. And then, the coefficient is classified into function of pressure and confirmed by the comparison between experiments and FE analyses using the other model. The FE analysis to predict the temperature distribution is performed by commercial software $DEFORM-3D^{TM}$. However, it might be impossible to measure directly the temperature distribution of forged part. Therefore, the comparisons between measured temperature and predicted values are performed with the hardness of Al6061-forged part.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.204-208
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• 2000

An approximate similarity theory has been applied to predict the forming load of non-axisymmetric forging of aluminum alloys through model material tests. The approximate similarity theory is applicable when strain rate sensitivity, geometrical size, and die velocity of model materials are different from those of real materials. Actually, the forming load of yoke, which is an automobile part made of aluminum alloys(Al-6061), is predicted by using this approximate similarity theory. Firstly, upset forging tests are have been carried out to determine the flow curves of three model materials and aluminum alloy(Al-6061), and a suitable model material is selected for model material test of Al-6061. And then hot forging tests of aluminum yokes have been performed to verify the forming load predicted from the model material, which has been selected from above upset forging tests. The forming loads of aluminum yoke forging predicted by this approximate similarity theory are in good agreement with the experimental results of Al-6061 and the results of finite element analysis using DEFORM-3D.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.7
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• pp.139-148
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• 1998

Internal and external heat sources will cause to deform to machine elements in the contact joint of structure, which results in the change of contact pressure distribution different from initial assembly. Heat induced variations of contact pressure will change the static and dynamic properties such as contact stiffness, damping as well as contact heat conduction in the structure In order to design and control the intelligent machine tool operating in variant conditions more sophisticatedly, the good prediction for the changes of prescribed properties are strongly required especially in the contact elements adjacent to the rotational or linear bearing. This paper presents some computational and experimental results in regard to static and dynamic characteristics of the press-fitted bush and shaft assembly which is a model of the bearing innerrace and shaft assembly. In the condition of heat generation on the outer surface of the bush, the effects of changes in the negative clearance and the heat flux on pressure distribution and dynamic properties are investigated. Results of this study show that the edge effect of the bush and the initial clearance have effects on the transient dynamic characteristics significantly.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.8
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• pp.100-105
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• 2000

In this study the structural design concepts of main parameters of a Cathode Ray Tube(CRT) such as frame spring and shadow mask were proposed to guarantee a failure-proof CRT under mechanical shock. With computer simulation and experiments some information on the structural design concept was obtained as followings: the frame and the shadow mask of the CRT needed designing to increase strength so double-beads shape at the corner of frame was newly designed for it, And the spring which interconnected frame with panel glass was required to deform elastically for the purpose of absorbing the shock energy in the direction of drop. A new type of spring 'twisting spring' was designed to achieve the flexibility in that direction. By using it the deformation energy of a shadow mask could reduced to some degree. To accomplish those simulations commerical codes Pam-Crash and I-DEAS were used and a typical CRT was analyzed as an example to prove the usefulness of this study.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.9
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• pp.32-40
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• 2004

This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. The system is composed of four main modules. The process planning and the die design modules consider several factors, such as the complexities of preform geometry, punch and die profiles, specifications of available multi former, and the availability of standard parts. They can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module an optimal design technique and horizontal split die were investigated for determining appropriate dimensions of components of multi-former die set. It is constructed that the proposed method can be beneficial for improving the tool life of die set at practice.

• Korean Journal of Metals and Materials
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• v.49 no.8
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• pp.664-670
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• 2011

3-ply Mg/Al/STS clad-metal was fabricated by the roll bonding process. An interfacial reaction layer was formed at the Mg/Al interface at and above $300^{\circ}C$ whereas no interfacial reaction layer was observed up to $400^{\circ}C$. The effect of the interfacial reaction layer on the mechanical and fracture properties in clad metals after heat treatments were investigated The chemical compositions were analyzed at the Mg/Al interface by an Energy dispersive X-ray analysis (EDX). A tension test was performed to examine the interfacial cracking properties. The Mg layer fractured first, causing a sudden drop of the stress and Al/STS layer continued to deform until the final fracture. Periodic cracks and crack propagation was observed at the reaction layer between Mg and Al.

• Journal of the Korean Society of Industry Convergence
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• v.22 no.4
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• pp.387-394
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• 2019

This paper presents an analytical study on the strength and stiffness of various types of truss structures. The applied models are triangular-like opened truss-wall triangular model (OTT), closed truss-wall triangular model (CTT), opened solid-wall triangular model (OST), and hypercube models defined as core-filled or core-spaced cube. The models are analyzed by numerical model analysis using DEFORM 2D/3D tool with AISI 304 stainless steel. Then, the ideal solutions for stiffness and strength are defined. Finally, the relative elastic modulus of the core-spaced model is obtained as 0.0009, which is correlated with the cancellous bone for the relative density range of 0.029-0.03, and the relative elastic modulus for the core-filled model is obtained as 0.0015, which is correlated with cancellous bone for the relative density range of 0.035-0.036. For the relative compressive yield strength, the OTT reasonably agrees with the cancellous bone for the relative density of 0.042 and the relative compressive strength of 0.05. The CTT and OST are in good agreement at the relative density of 0.013 and the relative compressive yield strength of 0.002. The hypercube models can be used for the cancellous bone for stiffness, and the triangular models can be used for the cancellous bone for strength. However, none of the models can be used to replace the compact bone because it requires much higher stiffness and strength. In the near future, compact bone replacement must be further studied. In addition, previously mentioned models should be developed further.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.5
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• pp.117-122
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• 2018

3D printing technology and its applications have grown rapidly in academia and industry. We consider a 3D printing system designed for the selective laser sintering (SLS) method, which is one of the powder bed fusion (PBF) techniques to build up the final product by layering sintered powder slices. Thermal distortion of printing products is a critical challenge in 3D printing. This study investigates temperature-dependent conformational behaviors of 3D printed samples of sintered poly-ether-ether-ketone (PEEK) powders using molecular dynamics simulations. The wear and chemical resistance properties of PEEK are understood, as it is a well-known biocompatible material used for implants. However, studies on physical phenomena at nanoscale in PEEK are rarely published in public. We simulate dissipative particle dynamics to elucidate how a cavity regime forms in PEEK at different system temperatures. We demonstrate how PEEK structures deform subject to the system temperature distribution.

• Transactions of Materials Processing
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• v.27 no.6
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• pp.331-338
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• 2018

Electrohydraulic forming (EHF) process is a high speed forming process that utilizes the electric energy discharge in fluid-filled chamber to deform a sheet material. This process is completed in a very short time of less than 1ms. Therefore, finite element analysis is essential to observe the deformation mechanism of the material in detail. In addition, to perform the numerical simulation of EHF, the material properties obtained from the high-speed status, not quasi static conditions, should be applied. In this study, to obtain the parameters in the constitutive equation of Al 6061-T6 at high strain rate condition, a surrogate model using an artificial neural network (ANN) technique was employed. Using the results of the numerical simulation with free-bulging die in LS-DYNA, the surrogate model was constructed by ANN technique. By comparing the z-displacement with respect to the x-axis position in the experiment with the z-displacement in the ANN model, the parameters for the smallest error are obtained. Finally, the acquired parameters were validated by comparing the results of the finite element analysis, the ANN model and the experiment.