• Transactions of Materials Processing
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• v.3 no.2
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• pp.189-201
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• 1994

This study aims detecting forming defects for the forming process of bearing rings, which is designed by and industry expert. The designed process consists of one forming operation for the outer ring and four operations for the inner ring. The thickness of the sheet used is 1.6mm, and is in between of thin sheet and bulk material. Here the rigid-plastic finite element method is applied to the analysis and design of the process without considering anisotropy of thin sheet. Thinning and folding defects are detected if the initially designed process is applied for manufacturing. So a new process is designed by referring the results of the FEM. It is confirmed that the industry expert agree the possibility of defects derived from FEM results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.03a
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• pp.19-30
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• 1995

The analysis had been already completed to detect forming defects for the forming processes of C/R bearing rings. But some unpredicted problems were found through the experiments. So expert redesigned new forming processes to prevent the problems and new analysis was began according to the new processes to find faults for the processes. The forming processes consist of 1 for the outer ring. 6 inner ring. The thickness of metal sheet used is changed to 1.5mm from 1.6mm. Elasto-plastric finite element method is applied to involve the effect of spring back . The most representative alteration is forming of two predents to assist later forming . Thining and distribution of high residual stress are derived from the results of simulations. It is confirmed that the industry expert agree the possiblilty of defects dervied from the new FEM results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03b
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• pp.121-129
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• 1996

This study aimsdetecting defects for the forming precesses of X2 spline, which is designed by an industry expert. The exist process consists of 3 runs and 7 operations with 3 heat treatments. The rigid-plastic FEM analysis was carried out to design a new process and some defects were found. Thus the design was modified to get better results. it is ocnfirmed that the industry expert agree the possibility of defects derived from the FEM results.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.5
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• pp.55-62
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• 2007

With the developments in knitting, manufacturing, and polymers, coated gloves have been evolved in a way to maximize occupational safety and functionality. In this paper, we have considered the PU-coating process for the glove knitted by Dyneema to reduce the occurrence of the defects due to air bubble. This paper classifies the types of defect due to air bubble and traces their forming mechanisms. The air between coating layer of glove and mold's surface forms the defects if it is not evacuated fully in the process of submerging into water. The defects can be suppressed or avoided by forming air-evacuating path on the surface of the molds.

• Journal of Korea Foundry Society
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• v.20 no.6
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• pp.368-376
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• 2000

Rheology forming technology has been accepted as a new method for fabricating near net shaped products with lightweight aluminum alloys. The rheology forming process consists of reheating process of billet, billet handling, filling into the die cavity and solidification of rheology formed part. The rheology forming experiments are performed with two different die temperatures ($T_d$ = $200^{\circ}C$, $300^{\circ}C$) and orifice gate type. The filling behavior and various defects of Al-Si materials with wear resistance (A357, A390 and ALTHIX 86S) fabricated in rheology forming process are evaluated in terms of alloying elements and surface non-uniformity. Finally, the methods to obtain the rheology formed products with high quality are described by solutions for avoiding the surface and internal defects.

• Transactions of Materials Processing
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• v.26 no.2
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• pp.95-100
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• 2017

In this study, the method of process design for side forming of a tooth part used for a component of automobile transmission was suggested using FE-simulations. To develop the side forming for the tooth part, in this paper, the shape factors of B.T.Pin was considered as design parameters. The shape factors of B.T.Pin were selected to be the round of pin, reinforced angle and reinforced length. Based on FE simulation results, appropriate shape factor without causing any defects was selected. In addition, to increase the strength of pin, the combination of shape factor having minimum stress after side forming was selected using FE-simulation. In addition, with design of a die set, cold side forming of the tooth part was experimented to estimate effectiveness of the designed B.T.Pin. From experiments, it was found that the tooth part with complete formation of the tooth was obtained without making any forming defects and punch fracture.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.3
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• pp.33-38
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• 2000

In process of tube spinning far shock absorber on vehicles, the selection of feed rate and rounding radius of forming roller and revolution speed of tube and forming roller, forming gap between die and forming roller are very important factors to obtain the optimal process result. In this paper, rigid-plastic FEM and UBET analysis are applied to verify effect of each factors by forming load. We can obtain the optimal conditions to prevent defects during processing.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.8
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• pp.212-219
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• 2002

The pipe with a long-neck flange is widely used in power plants, chemical plants, and shipbuilding companies. Now the pipe with a long-neck flange is manufactured by welding a thick flange to a pipe. But this long-neck flange pipe has some defects in the welding region such as unfitting and local thermal fatigue, which weaken the strength around the neck of the flange. Moreover, after welding the flange, the contacting surfaces of the flange have to be machined flat. So, that is uneconomical. Therefore, to solve the above problems of the long-neck flange pipe, a new process, which has no defects around the flange neck, is required. In this study, three forming processes are suggested to get an enhanced long-neck flange. First suggested process consists of conical forming and flange forming. Second and third suggested processes consist of the bulging of a long pipe locally heated by induction coils and the flange forming. The differences between second and third suggestions are the thickness and local heating area of the pipe. That is, the thickness of the initial pipe of third suggestion is larger than that of the final product, and the local heating area is smaller than that of second suggestion. These three suggestions for forming a long-neck flange are simulated by FE analyses with a commercial code DEFORM 2D. Especially, the theoretical result of FE analysis on the first suggestion for forming a long-neck flange is verified by the experiment with aluminum 6063 pipes. From the theoretical and experimental results, it is concluded that three suggested processes are very useful in order to manufacture the pipe with a long-neck flange without any defects.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.125-136
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• 2012

Wrinkle and fracture are two major defects frequently found in the sheet metal forming process. In this process there are more than one design attributes to optimize and several uncontrollable factors which cannot be ignored in determining the optimal values of design variables. Therefore, attempts to reduce defects through a traditional optimization technique are often led to failures. In this research, a new design method for reducing the wrinkle and fracture under uncontrollable factors is presented by using decision-making theory. To avoid the psychological difficulties in determining the scaling constants of the multi-attribute utility function by using the ordinary lottery questions, a pair-wise comparison procedure is adapted to avoid this problem. The effectiveness of the proposed method is illustrated through a robust design of sheet metal forming process of a side member of an automotive body.

• Journal of Ocean Engineering and Technology
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• v.13 no.4 s.35
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• pp.75-81
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• 1999

Roll forming process is simulated with a commercial FEM code LS-DYNA. The rolls are treated as rigid bodies rotating with a constant angular velocity. The strip and the rolls are modeled with 4-node plate elements. It is assumed that the nodes along the front end of the strip move along paths given by sine functions. It is found that the analysis can be applied to the optimal design of forming rolls. With these analyses, it is expected that forming defects can be avoided and process development efforts can be reduced.