• Transactions of Materials Processing
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• v.17 no.6
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• pp.420-428
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• 2008

The effect of loading path changes on the strain and mechanical properties of a commercial pure aluminum was studied using flat rolling and groove rolling. Material during flat rolling undergoes a continuous monotonic compressive loading, while one during groove rolling experiences a series of cross compressive loading. Four-pass flat rolling and groove rolling experiment are designed such that the aluminum undergoes the same amount of the strain at each pass. The rolling experiment was performed at room temperatures. Specimens for tensile test are fabricated from the plate and bar rolled. In addition, the strain distribution for the plate and bar cold rolled specimens is also calculated by finite element method. The results reveal that differences of loading path attributed by monotonic loading(flat rolling) and cross loading(groove rolling) significantly influence the mechanical properties such as yield stress, ultimate tensile stress, strain hardening and elongation. It is clear that the different loading path can give raise to change the deformation history, although it is deformed with same amount of strain for same material.

• Korean Journal of Materials Research
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• v.21 no.6
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• pp.320-326
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• 2011

Flat rolling of wire is an industrial process used to manufacture electrical flat wire, medical catheters, springs, piston segments and automobile parts, among other products. In a multi-step wire flat rolling process, a wire with a circular crosssection is rolled at room temperature between two flat rolls in several passes to achieve the desired thickness to width ratio. To manufacture a flat wire with a homogeneous microstructure, mechanical and metallurgical properties with an appropriate pass schedule, this study investigated the effect of each pass schedule (1stand ~ 4stand) on the microstructures, mechanical properties and widths of cold rolled high carbon steel wires using four-pass flat rolling process. The evolutions of the microstructures and mechanical properties of the widths of cold rolled wires during three different pass schedules of the flat rolling process of high carbon wires were investigated, and the results were compared with those for a conventional eight-pass schedule. In the width of cold rolled wires, three different pass schedules are clearly distinguished and discussed. The experimental conditions were the same rolling speed, rolling force, roll size, tensile strength of the material and friction coefficient. The experimental results showed that the four-pass flat cold rolling process was feasible for production of designed wire without cracks when appropriate pass schedules were applied.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.3
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• pp.554-570
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• 1990

he rolling contact behaviors between a smooth ball and a flat rough surface under dynamic load are intricately affected by many factors, such as the diameter of a ball, normal load and the roughness of a flat surface etc. Accordingly, the experimental study is done to find them on the base of elastic hysteresis loss as theoretical approach is very difficult. The experimental apparatus composed of damped-free vibration system is used. This paper investigates the damping characteristics on the rolling contact area through rolling friction force and logarithmic decrement versus displacement obtained in accordance with the variations of those factors, and presents a new experimental method to find out contact width using the relations of logarithmic decrement and rolling friction force with displacement.

• Transactions of Materials Processing
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• v.26 no.4
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• pp.228-233
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• 2017

In flat rolling mills, demands for precise process set-up and control are increasing than ever before. Consequently, it is imperative to establish a novel approach, which would provide valuable information regarding the detailed aspects of deformation behavior of the strip, and rolls during rolling. In this paper, we present a finite element (FE) approach for 3-D coupled analysis of the elastic-plastic deformation of the strip and the elastic deformation of rolls in the roll-stack of a mill stand.

• Transactions of Materials Processing
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• v.11 no.1
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• pp.24-35
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• 2002

Recent trend and future prospect of flat rolling of steel has been summarized based on the earlier reports. Key technology in the plate rolling is to have ultra fine microstructure having high resistance against crack propagation during application. Heavy accelerated cooling facility and high power rolling mill will be helpful to develope the high toughness steel. Precise modeling of properly prediction based on deformation and transformation imposed on microstructure of steel during processing is highly anticipated. For the hot strip rolling process, new trend is lies on the production of ultra-thin gauged hot strip to substitute cold rolled strip. For the substitution of cold rolled strip into hot rolled strip widely, high formable property of hot strip is highly required. For the formabilit, the ferritic rolling of extra low carbon steel under high lubricated condition is essential. Recently introduced semi-continuous thin slab and rolling mill line is very plausible to develope those kinds of products easily In the view groin facility combination. New idea to modify the existing continuous hot strip mill line to produce the ultra thin-gauged hot strip in an economic way is suggested in this report.

• Transactions of Materials Processing
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• v.8 no.2
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• pp.178-187
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• 1999

The Cross rolling between flat jaws, as a kind of hot forging, is the forming method to make the axisymmetric multi-step shaft by its rotation and pressure between flat jaws which move in opposite direction. The purpose of this study is to propose the optimal geometric data for shape development of the forward forming region. All data described on this paper are quantified by experiment from initial shape design to final shape development. As the result, proper geometric data are proved that lenth of the first forming area in the forward forming region is 1.5 times larger than circumference of work-piece and the progress angle changes 3 times smoothly.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.8
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• pp.35-41
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• 2010

White Etching Layer(WEL) is a phenomenon that occurs on the surface of rail due to wheel/rail interactions such as excessive braking and acceleration. Rolling Contact Fatigue(RCF) cracks on the surface of rail have been found to be associated with WEL. In this study, we have investigated RCF damages of white etching layer using twin disc testing and fatigue analysis. These tests consist of wheel flat tests and rolling contact fatigue tests. WEL has been simulated by wheel flat test. It has been founded that the WEL with a bright featureless contrast is formed on the surface of specimen by etching. Rolling contact fatigue test was conducted by using flat specimens with the WEL generated by the wheel flat test. It has been observed that two types of cracks occur within the specimen. The contact fatigue test was simulated in 2D elastic-plastic FE simulations. Based on loading cycles obtained from the finite element analysis, the fatigue life analysis according to the thickness variation of WEL was carried out. The longest fatigue life was observed from the thickness of 20um.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.156-159
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• 2003

Surface normal vector and surface velocity are very important parameters to simulate rolling processes precisely. In this study, Local displacement functions are constructed for each node on the contact surface and parameters are found by the least square fitting of displacement on the neighbor nodes. Deformation gradient tensor is calculated from the displacement function and surface normal vector and velocity also can be derived. Flat rolling simulation model is presented on the basis of the suggested contact scheme. Series of rolling process simulation are carried out and the results are compared with the experiments.

• Transactions of Materials Processing
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• v.26 no.4
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• pp.234-239
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• 2017

A general approach is proposed for 3-D coupled FE analysis of the deformation of the strip and rolls in flat rolling. FE formulation, schemes for the treatment of contact occurring in a cluster of deforming objects, and the solution strategy are described in detail. The validity of the approach is examined through comparison with observed measurements. The approach is applied to the analysis of deformation in a four-high and six-high mill.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.62-65
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• 2009

There have been strong demands for micro size screw with high precision due to miniaturization and integration trends for electronic products such as Hard Disk Drives. The thread rolling process for screw manufacturing are lower unit cost, reduced material utilization, and superior mechanical properties compared to the machining process. But little work has been done on the thread rolling of micro size screw. In this paper, we investigate thread rolling process using Finite Element Analysis (FEA) and parameter study for screw manufacturing. And we also carried out compression tests to obtain the material property and to implement into the FE tool for the numerical simulation. In case that parameter of relative position oldies is half length of pitch for maintaining the continuous thread profiles, we found that shear friction factor was 0.9 during the thread rolling process using FEA. We are trying to develop the thread rolling process using the FE-simulation to manufacture screws which have been commonly produced from the industrial level fabrication at present.