• Journal of the Korean Society for Precision Engineering
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• v.22 no.9 s.174
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• pp.41-48
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• 2005

In this study, to improve the formability of the rear floor in series stamping process, the method for predicting the temperature of tools and steel sheet is proposed using FE analysis. To do this, tensile tests and straight pulling friction tests of three steel sheets are carried out at temperatures up to $300^{\circ}C$, and the effect of temperature on the tensile properties and the characteristics of friction are examined. The steel sheets have a higher n-value in the temperature range of about $50^{\circ}C$, and it is related to the maximum uniform elongation. Also, the blue shortness occurs in the temperature range of about $150^{\circ}C$. When the temperature is higher than $200^{\circ}C$, the friction coefficient increase with increasing temperature. From the FE-simulation, the effects of the punch temperature considering heat expansion in the number of stamping are examined and discussed. The technique developed in this study fur estimating tool temperature can be used to develop more feasible ways to improve continuous productivity in series stamping process.

• Transactions of Materials Processing
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• v.23 no.6
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• pp.357-362
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• 2014

The purpose of the current study is to predict the hardness distribution in steel products after hot stamping using a quench factor analysis(QFA) coupled with FE-simulations. QFA is a method to predict properties such as hardness and tensile strength based on time-temperature-property(TTP) curves and can determine properties based on the temperature histories. The constants($K_1{\sim}K_5$) of QFA were determined using hardness data obtained after various cooling rates. In the current study, a rear side member was selected for evaluation and FE-simulations were performed to obtain the temperature histories during hot stamping. The predicted temperature data were imported into the QFA to calculate the hardness distribution of the hot stamped parts. A hot stamping experiment of the rear side member was conducted to verify the predicted hardness. The simulation results show good agreement with the experimental measurements.

• Korean Journal of Materials Research
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• v.20 no.9
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• pp.478-482
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• 2010

A series of molecular dynamic (MD), finite element (FE) and ab initio simulations are carried out to establish suitable modeling schemes for the continuum-based analysis of aluminum matrix nanocomposites reinforced with carbon nanotubes (CNTs). From a comparison of the MD with FE models and inferences based on bond structures and electron distributions, we propose that the effective thickness of a CNT wall for its continuum representation should be related to the graphitic inter-planar spacing of 3.4${\AA}$. We also show that shell element representation of a CNT structure in the FE models properly simulated the carbon-carbon covalent bonding and long-range interactions in terms of the load-displacement behaviors. Estimation of the effective interfacial elastic properties by ab initio simulations showed that the in-plane interfacial bond strength is negligibly weaker than the normal counterpart due to the nature of the weak secondary bonding at the CNT-Al interface. Therefore, we suggest that a third-phase solid element representation of the CNT-Al interface in nanocomposites is not physically meaningful and that spring or bar element representation of the weak interfacial bonding would be more appropriate as in the cases of polymer matrix counterparts. The possibility of treating the interface as a simply contacted phase boundary is also discussed.

• Transactions of Materials Processing
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• v.17 no.3
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• pp.170-181
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• 2008

The shape of rectangular cup used for Ni-MH(Nickel-coated Metal Hydrogen) battery for hybrid car looks quite simple, but the forming process of extruding and setting up process design are highly difficult. Furthermore, there are few concrete reports on the rectangular deep drawn cup as part of hybrid vehicles till now. In this study, process design for rectangular cup in the multi-stage deep drawing process is carried out, and FE analysis is also preformed based on the result of the process design. From the simulation result, some unexpected problems such as earing, wrinkling and excessive thickness changes of the intermediate blank occurred. To overcome these failures, a series of modification for punch shape in the forming process design are completed and applied. Considering the modified punch shape in the multi-stage deep drawing process, additional FE analysis is also carried out and the simulation result is verified in view of the deformed shape, thickness change and effective strain distribution. The result of FE analysis with the improved process design confirmed not only reducing thinning of wall and possibilities of failure but also improving the quality of drawing product through the modification of punch shape.

• Transactions of Materials Processing
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• v.21 no.4
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• pp.228-233
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• 2012

In this study, powder compaction of AZO (alumina doped zinc oxide) powder was performed with a MTS 810 test system using a cylindrical die having a diameter of 10mm. Pressure-density curves were measured based on the load cell and displacement of the punch. The AZO powder compacts with various densities were formed to investigate the mechanical properties such as fracture stress of the AZO powder as a function of the compact density. Two types of compression tests were conducted in order to estimate the fracture stress using different loading paths: a diameteral compression test and a uniaxial compression test. The pressure-density curves of the AZO powder were obtained and the fracture stress of the compacted powders with various densities was estimated. The results show that the compact pressure dramatically increases as the density increases. Based on the experimental results, calibration of the modified Drucker-Prager/Cap model of the AZO powder for use in FE simulations was developed.

• Advances in biomechanics and applications
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• v.1 no.1
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• pp.23-40
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• 2014

This paper examines the blood chamber of a left ventricular assist device (LVAD) under static loading conditions and standard operating temperatures. The LVAD's walls are made of a temperature-sensitive polymer (ChronoFlex C 55D) and are covered with a titanium nitride (TiN) nano-coating (deposited by laser ablation) to improve their haemocompatibility. A loss of cohesion may be observed near the coating-substrate boundary. Therefore, a micro-scale stress-strain analysis of the multilayered blood chamber was conducted with FE (finite element) code. The multi-scale model included a macro-model of the LVAD's blood chamber and a micro-model of the TiN coating. The theories of non-linear elasticity and elasto-plasticity were applied. The formulated problems were solved with a finite element method. The micro-scale problem was solved for a representative volume element (RVE). This micro-model accounted for the residual stress, a material model of the TiN coating, the stress results under loading pressures, the thickness of the TiN coating and the wave parameters of the TiN surface. The numerical results (displacements and strains) were experimentally validated using digital image correlation (DIC) during static blood pressure deformations. The maximum strain and stress were determined at static pressure steps in a macro-scale FE simulation. The strain and stress were also computed at the same loading conditions in a micro-scale FE simulation.

• Journal of the Korean Magnetics Society
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• v.11 no.6
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• pp.272-277
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• 2001

A spin valve structure of Ta/NiFe/CoFe/Cu/CoFe/Ru/CoFe/FeMn/Ta which has a synthetic antiferromagnet (CoFe/Ru/CoFe), was fabricated by using a magnetron sputtering system. The thickness and composition of magnetic free and pinned layers affect the magnetic properties such as exchange interaction strength of each layer and so on. Even though Rutherford Backscattering Spectrometry (RBS) has advantages of quantitative and non-destructive analysis, it is almost impossible to determine the thickness and composition of magnetic thin films using lBS because of its poor mass resolution for a higher atom number (Z>20). In this study, quantitative analysis of the element composition and thickness for the spin valve sample was performed by combining both Proton Induced X-ray Emission Spectrometry (PIXE), which is one of element specific analysis techniques, and grazing-exit RBS with a highly improved depth resolution and absolute quantitative analysis. For the quantitative analysis, standardization of PIXE was carried out with NiFe, CoFe, and FeMn layers, which are one of constituent layers of spin valve films. Through PIXE standardization and the aid of PHE experimental results of the spin valve sample, ire overlapped signal in a grazing-exit RBS spectrum were successfully resolved and the thickness of the Ru layer was determined with a resolution of ∼1 .

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.403-407
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• 2009

In this work, finite element investigations were carried out to manufacture a seamless aluminum liner without crack generation using four-stage deep drawing followed by two-stage ironing process. In order to predict the crack generation during the liner manufacturing process, the Normalize Cockroft-Latham(NCL) which is one of ductile fracture criteria was adopted. In addition, the tensile tests were carried out to obtain the critical value of NCL by comparing the experimental and FE simulation results. From this, various case studies based on FE simulation were carried to obtain the optimum die designs which can prevent the crack generation during ironing processes. Finally, the aluminum liner was successfully made using obtained die designs so that requirements were met in terms of thickness and height of the liner.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.8
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• pp.1291-1297
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• 1997

Elastic-plastic finite element(FE) simulation was performed for polycrystalline solids subjected to plane strain tensile loading. Using Asaro's double slip crystal plasticity model, the polycrystalline solids were modeled by assigning different initial slip directions to each grain. From the FE calculations, the microscopic deformation characteristics of polycrystalline solids were analyzed. Moreover, the effect of grain size and grain boundaries on the deformation characteristics were clarified.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.25-28
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• 2004

A fracture was generated by change of clearance and deterioration of material properties on the sheet metal through temperature. This paper describes the results of a prediction about the temperature of the sheet metal during continuous stamping process, because the temperature increase of the sheet metal has a detrimental effect on formability. To analyze the temperature increase of the sheet metal during continuous stamping process, tensile and friction tests were performed from room temperature to 300$^{\circ}C$ at warm condition in this study. As temperature increase, tensile strength, elongation, strain hardening exponent and anisotropy coefficient for each specimens were decreased. On the other hand, friction coefficients were increased. From the FE-simulation results, temperature upward tendency was identified on dies and sheet metal. These observations are rationalized on the basis of the material properties, friction coefficient vs. temperature relationship for the sheet.