• Proceedings of the KSME Conference
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• 2000.04a
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• pp.230-235
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• 2000

By using the finite element method, the Oyane's ductile fracture integral I was calculated from the histories of stress and strain according to every element and then the forming limit of hydroforming process could be evaluated. The fracture initiation site and the forming limit fer two typical hydroforming processes, tee extrusion and bumper rail under different forming conditions are predicted in this study. For tee extrusion hydroforming process, the pressure level has significant influence on the forming limit. When the expansion area is backed by a supporter and bulged, the process would be more stable and the possibility of bursting failure is reduced. For bumper rail, the ductile fracture integral I is not only affected by the process parameters, but also by the shape of preforming blank. Due to no axial feeding on the end side of the blank, the possibility of cracking in hydroforming of the bumper rail is influenced by the friction condition more strongly than that of the tee extrusion. All the simulation results show reasonable plastic deformation, and the applications of the method could be extended to a wide range of hydroforming processes.

• Journal of Powder Materials
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• v.13 no.6 s.59
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• pp.408-414
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• 2006

[ $MoSi_2$ ] alloys with Al, B or Nb were prepared by an advanced consolidation process that combined mechanical alloying with pulse discharge sintering (complex forming) to improve the mechanical properties. Their microstructure and mechanical properties were investigated. The $MoSi_2$ alloys fabricated by complex forming method showed very fine microstructure when compared with the sample sintered from commercial $MoSi_2$ powders. Alloys made from powders milled in Ar gas had fewer silica or alumina phases as compared to their counterparts sintered from powders milled in air. In densification of the sintered body, addition of B was more effective than Al or Nb. Both Victors hardness and tensile test indicated that the alloy fabricated by the complex forming method showed better properties than the sample sintered from commercial $MoSi_2$ powders. The Al added alloy sintered from the powders milled in air had the superior mechanical properties due to the suppression of $SiO_2$ and formation of fine $Al_2O_3$ particles.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2011.06a
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• pp.261-262
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• 2011

Conventional automatic transmission system includes a hydrodynamic torque converter to transfer engine torque from an engine crank shaft to a rotatable input members, which are of complex design permitting them to serve several functions. These are clutches or brakes which couple the rotatable input member to member of a planetary gear set. The annulus gear for an automatic transmission is a monolithic gear having a set of gear teeth formed on an inner surface which is coupling with a set of planetary gear. In this study, the flow forming method is applied to the manufacturing of the annulus gear. This cold forming is proper method in order to manufacture dimensionally precise and round hollow components such as annulus gear. By pre-calculated amount of wall thickness reduction, the seamless tube of SAE1026 is compressed above its yield strength, plastically deformed and made to flow in several roll passes. According to this study, the desired geometry of the annulus gear can be achieved when the outer diameter and the thickness of the tube are properly decreased by compressed roll passes and the available material volume is easily forced to flow longitudinally over the shape of mandrel.

• Transactions of Materials Processing
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• v.17 no.7
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• pp.491-495
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• 2008

Incremental forming path to manufacture a thick concave steel plate using the line array roll set is designed. To find the optimum forming path, the forming processes are simulated by the finite element method. A general-purpose commercial software, MSC MARC is used. A modeling with 8-node hexahedral elastic-plastic solid is performed to predict accurate springback and the analysis process was composed of 18 passes. The proposed forming paths are verified through experiments carried out in the prototype line array roll set. It is found that the process can be successfully applied to the fabrication of the dual curvature ship hull plate.

• Journal of Power System Engineering
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• v.8 no.3
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• pp.23-29
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• 2004

In this paper, a finite element formulation using dynamic-explicit time integration scheme is used for numerical analysis of Hydro-forming processes. The lumping scheme is employed for the diagonal mass matrix and dynamic explicit formulation. Hydro-forming process for auto-body panel forming is analyzed by using dynamic-explicit finite element method. Further, the simulated results of the Hydro-forming processes are shown and discussed. Its application is being increased especially in the automotive industrial area for the cost reduction, weight saving, and improvement of strength.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03a
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• pp.172-184
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• 1996

Superplastic forming of thin sheet into complex shape is an important manufacturing process especially in aerospace industry. The main interest in modeling the superplastic forming process is to predict the forming pressure cycle to maintain optimum strain rate and the resulting thickness distribution. Many researchers have attemped to model superplastic forming using the various techniques including finite element method. But in most of their researches have disregarded the strain hardening effect which which occurs in several superplastic materials. In this study ABAQUS finite element code was used for prediction of process variables for axisymmetric cup forming of Supral 100 and 7075Al alloys considereing strain hardening. The performance of numerical results were compared with the experimental results.

• Transactions of Materials Processing
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• v.21 no.3
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• pp.151-159
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• 2012

Finite element simulations were conducted to investigate the influence of grain growth in the superplastic blow forming process. A microstructure-based constitutive model considering grain growth effects is proposed and used in the simulations. Also, a grain growth rate equation accounting for both static and dynamic grain growth is implemented. The simulations were made using a 2D plane-strain model for constrained blow forming and an axisymmetric model for free bulging. These two models showed different features during the forming stages. However, the forming pressure-time curve and the thickness distribution obtained by both simulations explained well the deformation hardening induced by the grain growth during superplastic forming. This study shows that grain growth is an important factor in determining the material behavior during superplastic deformation.

• 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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• 1994.06a
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• pp.1-9
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• 1994

Three recent developments made at Rensselaer in sheet material forming processes are briefly reviewed in this paper. These advances represent three broad disciplines of Process Simulation, Forming Processes, and Computer-Aided Measurement Methods. The first development deals with simple and quick computer simulation of 2D sheet forming process without depending on popular finite element analysis methods. An analytical method based on a thin shell theory accounts for bending and unbending effects, and is capable of simulating practical sheet metal forming processes under the plane strain condition. The second area is concerned with innovative methods to improve formability of sheet materials by temperature gradient forming. The drawing limit is increased by such an improved temperature gradient forming process. The third and final area deals with a totally new experimental technique to capture 3D geometry data and measure strain distributions of sheet metal parts using a digital 35mm SLR camera.

• Journal of the Korean Society of Safety
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• v.15 no.3
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• pp.7-13
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• 2000

Forming characteristics of tailored blank are mostly effected by the welding method. Recently, laser welding is widely used for the tailored blank. However, tensile and forming characteristics vary due to welding conditions such as welding speed, heat flux etc. The objective of this paper is to evaluate the effect of welding speed on the tensile and forming characteristics of laser welded tailored blank. For this purpose, tailored blank specimens with different welding speed were prepared and tensile tests were performed. Also forming tests such as LDH and OSU test, were performed to evaluate the effect of welding speed on the forming characteristics. Finally, forming limit diagrams were obtained for different welding speed.