• Transactions of Materials Processing
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• v.9 no.2
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• pp.152-158
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• 2000

A finite element analysis has been performed to investigate the effect of die clearance on shear planes in the fine blanking of a part of automobile safety belt. For the analysis, S45C is selected as an material, which is used in manufacturing the part of automobile safety belt, and Cockcroft-Latham fracture criterion is applied. Effect of die Clearance on die-roll width, die-roll depth, burnish zone, and fracture zone has been investigated in the finite element analysis by a rigid-plastic FEM code, DEFORM-2D. From the analysis, it has been found that die-roll depth and depth of the shear plane increase with increasing die clearance. And the burnish zone decreases with increasing die clearance, but the variation of fracture zone is opposite to that of burnish zone because the increase in die clearance requires less fracture energy. Theoretical predictions are compared with experimental results. There is a good agreement between theory and experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.40-44
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• 1999

A finite element analysis has been performed to investigate the effect of die clearance on shear planes in the fine blanking of a part of automobile safety belt. For the analysis S45$^{\circ}C$ is selected as an material which is used in manufacturing the part of automobile safety belt and Cockcroft-Latham fracture criterion is applied, Effect of die clearance on die-roll width die-roll depth burnish zone and fracture zone has been concentrately investigated in the finite element analysis. From the analytical results it has been found that die-roll width and depth of the shear plane increase with increasing die clearance. And the burnish zone has been concentrately investigated in the finite element analysis. From the analytical results it has been found that die-roll width and depth of the shear plane increase with increasing die clearance. and the burnish zone decreases with increasing die clearance but the variation of fracture zone is opposite to that of burnish zone because the increase in die clearance requires less fracture energy Theoretical predictions are compared with experimental results, There is a good agreement between theory and experiment

• Transactions of Materials Processing
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• v.26 no.3
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• pp.156-161
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• 2017

In this study, the reason of die fracture occurring in hot forging of an aluminum fixed scroll was studied, based on experiments and finite element predictions. The material is assumed to be rigid-viscoplastic, and the die is rigid for the finite element predictions. The stress in the tension at the wrap root is known to cause brittle fracture, and the increase in the tensile stress is owing to the unbalanced filling of material into the die cavities between both sides of the warp. Based on the empirical and numerical achievements, the effects of geometrical parameters of the material on the die fracture were examined to find practical measures for elongated die life. It has been shown from the parametric study that the material with the optimized trapezoidal cross-section, which can be easily made during cutting or the optimized cylindrical billet with its eccentric placement in the die cavity, can considerably reduce the magnitude of the tensile stress around the die corner fractured, indicating that economical manufacturing with reduced number of stages and elongated die life can be realized at once using the optimized practical initial material.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.124-127
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• 2009

In this paper, a longitudinal die insert fracture which occurred during cold forging of a high strength ball-stud with a sound die design nearly optimized empirically for relatively low strength material of SCM435 is introduced and the reason is revealed. A comparative study between SCM435 and ESW105 is quantitatively made using a thermoelastic finite element method for die structural analysis coupled with a forging simulator theoretically based on a rigid-plastic finite element method. It has been shown that the longitudinal die insert fracture caused from non-optimized value of shrink fit, emphasizing that the die optimal design is inevitable for cold forging of high strength materials.

• Journal of the Korean Society for Heat Treatment
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• v.26 no.4
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• pp.178-184
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• 2013

The effects of thickness and surface grinding condition on the fracture strength of Si wafer with a thickness under $100{\mu}m$ were investigated. Fracture strength was measured by ball breaker test for about 330 dies (size: $4mm{\times}4mm$) per each wafer. For statistical analysis of the fracture strength, scale factor was determined from Weibull plot. Ball breaker fracture strength was observed to increase with decreasing thickness of silicon die. For the silicon dies of different surface conditions, ball breaker fracture strength was high in the order of polished, ground (#4800), and ground (#320 grit) specimen. Probabilistic fracture strength (i.e., scale factor) increased with decreasing surface roughness of silicon die.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.11 s.188
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• pp.78-84
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• 2006

The objective of this study is to design the optimal die profile that can prevent material fracture in the tube drawing process for automobile steering input shaft. First, the CDV(Critical Damage Value) of material is obtained by the compression test and FE-analysis. The occurrence of fracture is estimated by the FE-analysis considering the CDV. In order to achieve the objective of this study, optimization technique and FE-analysis are applied. FPS(Flexible Polyhedron Search) method, which is one of the non-gradient optimization techniques often used in engineering, is used to search optimal die profile. The drawing die profile is represented by Bezier-curve to generate all the possible die profile. Using FPS method and FE-analysis the optimal drawing die profile is determined. To verify tile effectiveness of the redesigned optimal die, the tube drawing experiment is performed. In the experimental result, it is possible to produce sound product without material fracture using the redesigned optimal die.

• Design & Manufacturing
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• v.15 no.1
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• pp.41-47
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• 2021

The Fine Blanking process is an effective precision shearing process that can obtain a smooth cutting surface and high product precision through a single blanking process. It is widely used in various manufacturing fields. However, shearing through this fine blanking process is only intended to minimize burrs, die rolls and fracture surfaces and does not completely remove them. Therefore, it is necessary to study the minimization of burrs, die rolls and fracture surfaces in the fine blanking process. In this study, a study was conducted on the relationship between the fracture surface and process conditions that occurred during product production using the fine blanking process. For this purpose, the shape of the V-ring indenter, the distance to the punch, and the pressure force, clearance, shear rate, and physical properties of the material were selected as process and design variables, and the relationship with the fracture surface according to each process and design condition was tested. It was analyzed through the Experimental Design Method.

• Elastomers and Composites
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• v.22 no.3
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• pp.213-218
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• 1987

In this study, the rheological properties of a partially valcanized black filled EPDM were investigated as a function of degree of crosslinks using capillary rheometer. In order to obtain the samples having various degree of crosslinks between 0 and 6 percent, the vulcanization kinetics was also studied by Monsanto rheometer. The results showed that the die swell ana the pressure drop at the capillary entrance and exit increase nearly linearly with the increase in degree of crosslinks. However, melt fracture occurred at a lower shear rate for the samples of higher degree of crosslinks. These results were discussed in terms of the melt elasticity produced at the entrance region of capillary by the partial vulcanization. It is also interesting to note that the fluctuation of die swell during the practical extrusion or calendering process in the factories can be caused by the partial vulcanization occurred during the process.

• Design & Manufacturing
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• v.11 no.1
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• pp.26-29
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• 2017

Burrs generated during shear forming such as notching and piercing may cause lifting during product assembly, which may deteriorate the productivity and quality of products. In this study, various shear angles and variable clearances between the punch and the die were applied in experimental notching tests to investigate the shear fracture surface and the burr height due to various conditions. The experimental results show that the clearance has the greatest effect on shear and fracture surfaces. It is considered that the height of the shear section increases slightly as the shear angle increases.

• Journal of the Microelectronics and Packaging Society
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• v.18 no.1
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• pp.15-21
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• 2011

In this study, flexural strength and fracture behavior of silicon die from single crystalline silicon wafer were investigated as a function of thickness. Silicon wafers with various thickness of 300, 200, 180, 160, 150, and 100 ${\mu}m$ were prepared by mechanical grinding and polishing of as-saw wafers. Flexural strength of 40 silicon dies (size: 62.5 mm${\times}$4 mm) from each wafer was measured by four point bending test, respectively. For statistical analysis of flexural strength, shape factor(i.e., Weibull modulus) and scale factor were determined from Weibull plot. Flexural strength reflecting both statistical fracture probability and size (thickness) effect of brittle silicon die was obtained as a linear function of die thickness. Fracture appearance was discussed in relation with measured fracture strength.