• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.575-578
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• 2000

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation for the die wear is too hard because the prediction of the die wear is determined with many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard's wear model in order to reduce the rapid wear rate that is generated for the backward extrusion product exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat, angle, and round of the punch nose part. As the flat and angle of the punch nose are larger, the surface expansion is reduced. and, the wear rate is decreased according to the reduction of the punch round. These results obtained through this study are applied to the real manufacturing process, it is implemented the reduction of the wear rate.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.10
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• pp.180-187
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• 2004

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation fur the die wear is too hard because the die wear is caused by many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard wear model in order to reduce the rapid wear rate that is generated for the backward extruded products exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat diameter, angle, and round of the punch nose part. As the flat diameter and angle of the punch nose are larger, the surface expansion is reduced and the wear rate is decreased according to the reduction of the punch round. These results obtained through this study can be applied to the real manufacturing process.

• Transactions of the Korean Society of Mechanical Engineers
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• v.3 no.4
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• pp.164-172
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• 1979

Experimental and numerical results concerning the flat punch indentation to semi-infinite body with partially constrained free surface are presented The distributions of slip line directions are predicted by Moire fringe analysis using Vinckier's method. A mumerical study is made of the same problem by finite element method and the results are compared with the experimental results. It is shown that the contour feature of possible slip line field is similar to that of well-known Prandtl indentation sloution.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.761-765
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• 1996

This paper describes the forging of circular tooth profiled gears as a series of development of simulator for non-axisymmetric parts that being used at the pump pulley, timing belt pulley etc. in automobiles. The half pitch of gear is divided into 6 deformation regious and kinematically admissible velocity fields for those regions are proposed. The neutral surface is introduced torepresent inner flow of material during forging operation with flat punch and, for each step, it is assumed as a circle. The upper bound solutions obtained from the suggested kinematically admissible velocity fields are in good agreement with experimental results and they are useful to predict the capacity of forging press for forging of circular gears.

• Bulletin of the Society of Naval Architects of Korea
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• v.5 no.1
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• pp.1-7
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• 1968

In this problem the ragid punch in the form of a flat-ended circular cylinder of unit radius is cemented to the stress free surface of an elastic half-space. An axial load P is then applied to the punch to force it into half-space to depth $\varepsilon$. It is assumed that the adhesive between the punch and can be reduced to the system of Abel type integral equations which are equation (13) and (14). It is also shown that the stress and displacement components on the portions of boundary where they are not prescribed can be expressed in terms of $\phi(t)$ and/or $\phi(t)$ which are introduced in equation (9) and (10). Those functions can be obtained from the solution of the system of integral equations (13) and (14).

• Structural Engineering and Mechanics
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• v.78 no.2
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• pp.135-143
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• 2021

In this study, continuous contact problem in the functionally graded (FG) layer loaded with a FG flat punch resting on the elastic semi-infinite plane was analyzed by the finite element method (FEM). It was assumed that the shear modulus and density of the layer and punch varied according to exponentially throughout their depth. FG layer's weight was included to the problem and additionally all surfaces were considered as frictionless. Analysis of FG materials was performed with a special macro which was added to the ANSYS program. Firstly, the shear modulus of the punch was considered to be very rigid and the results of initial separation load (λcr) and distance (xcr) were compared with the analytical solution. Afterwards, results obtained from the contact analysis made according to the inhomogeneity parameters (β, γ) between FG punch-FG layer which had been unprecedented in the literature were discussed. As a result, FG punch's stress values at the punch edges where stress accumulations occurred were found to be smaller than the rigid punch. The security of the structure, longer life of the material and ease of production are directly related to the reduction of the stress values. The results obtained in this study are important in this respect. Also this work is the first study that investigates the effect of FG punch on the FG layer.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.385-388
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• 2000

During the deep drawing process an initially flat blank is clamped between the die and the blank holder after which the punch moves down to deform the clamped blank into the desired shape. In general, sheet metal forming may involve stretching, drawing, bending or various combinations of those basic modes of deformation. The deformation problems of sheet metal working involve non-linearity in geometry and material. In this work, The punch load and thickness strain of electro-galvanized sheet steel (SECD) for elliptical deep drawing are examined under the various process conditions including, punch shape radius, die shape radius. The changes of punch load and thickness strain distribution of the deformed elliptical cup are affected by the size of each die shape radius.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.6 s.177
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• pp.1565-1574
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• 2000

Surface edge crack subjected to contact stresses is analysed. A punch with corner radii is considered to press the semi-infinite plane. Partial slip problem is solved when a shear force is applied to the punch. Dislocation density function method is used to solve the present mixed mode crack problem. The crack length of positive K1 is examined, which is affected by the ratio of the flat portion to the total width of the punch. Surface traction during one cycle of the shear force is evaluated to simulate the fretting condition. The compliance change of the contact surface is also investigated during the shear cycle. It is found that the crack grows during only a part of the cycle, which may be termed as effective period of crack growing. A design method for restraining the fretting failure is discussed, from which recommendable geometry of the punch is suggested.

• Journal of the Society of Naval Architects of Korea
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• v.45 no.2
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• pp.157-167
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• 2008

Six smooth flat tensile specimens and eighteen punch specimens with three different thicknesses were machined from steel of JIS G3131 SPHC. In addition to punch tests, incremental tensile tests were conducted to obtain average true flow stress - logarithmic true strain curves. Through parametric FE simulations for the tensile specimens, material parameters related to GTN model were identified. Using indenters with three kinds of radius, punch tests were carried out to obtain fracture characteristics of punch specimens. Numerical analyses using both fracture models, GTN and $J_2$ plasticity model, gave that the former estimated well the fracture of punch specimen but the latter did not. A new concept for critical size of plate elements was introduced based on minimum relative sharpness between contact structures. Consequently, a new criterion for critical element size was proposed to be less than 20% of minimum relative radius of interacting structures.

• Journal of Advanced Marine Engineering and Technology
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• v.33 no.2
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• pp.295-303
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• 2009

Forging of square spline was investigated by using finite element methods in this study. Spline is widely used by torque transmitter in the fields of automobile, aircraft, and shipping etc. Friction on the surface of die is regarded as the most important factor to improve the dimensional accuracy for complete forming of spline teeth. Finite element simulation was carried out to improve the formability of the spline, especially remove unnecessary burrs which were extruded in gap between the die and the punch. To remove the burrs, various friction factors are considered on the surfaces of the die in the simulations and punch flat surface was designed. The simulated results were compared with experimental ones. As a results, it is possible to control the growth of burrs and improve formability of spline teeth by applying various friction factors and design of punch flat surface.