• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.30.2-34
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• 1999

The hydroforming technology has gained in importance over the last few years, because of its potential for substantial weight avings costs reduction and quality improvement such as collision property, shape fixability and rigidity of white body. However, in comparison with the traditional sheet forming process, the hydroforming is much younger and the main development efforts were made in the last 15 years. The new technology, high pressure tublar hydroforming in particular, involves many process parameters to be optimized. This paper covers a brief overview of the hydroforming simulator as well as design of die and tools. The effects of typical parameters such as internal pressure and axial compression stroke are presented. Moreover, the conditions of forming failure occurrences such as fracture and wrinkle are examinated.

• Transactions of Materials Processing
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• v.20 no.8
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• pp.601-610
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• 2011

Based on the facts that AZ31 magnesium alloy can be blow formed just like superplastic aluminum alloys and that most superplastic alloys fail by cavitation, the present study was undertaken to investigate the cavitation behavior of a fine-grained AZ31 sheet during blow forming at the elevated temperature. Other points of interest included the much lower strain rate and temperature dependencies of the magnesium alloy compared with conventional superplastic alloys. It was also aimed to find if cavitation in the AZ31 alloy can be suppressed by hydrostatic pressure, as is the case in most superplastic alloys. Interestingly, the application of hydrostatic pressure did not increase the blow formability of AZ31 sheet, even though it reduced the degree of cavitation. A possible reason for this behavior is discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.139-142
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• 2009

As important mechanical elements, gears have been used widely in power transferring systems such as automobile transmission and there have been several researches trying to make gear parts with cold or warm forging in order to reduce cost and time required to gear manufacturing process. Although forging processes of spur and bevel gears have been developed as practical level owing to active previous researches in Korea, the manufacturing of helical gear has been still depended on traditional gear cutting processes such as hobbing, deburring and shaving. In order to manufacture helical gears with cold forging process, a research project supported by government has been conducted by Daegu university, KIMS and TAK and this paper deals with effects of back pressure forming technique to cold forging of helical gear as a fundamental research.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2006.06a
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• pp.325-326
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• 2006

In this study, in order to develop piezoelectric device for multilayer piezoelectric ultrasonic motor, low temperature sintering $Pb(Mn_{1/3}Nb_{2/3})_{0.02}(Ni_{1/3}Nb_{2/3})_{0.12}(Zr_{0.48}Ti_{0.52})_{0.86}O_3$ system ceramics were fabricated according to the variations of forming pressure of casting sheet. At the 300[$kgf/cm^2$] forming pressure, the maximum density of 7.8[$g/cm^3$] was obtained. At the 350[$kgf/cm^2$] forming pressure, the maximum values of effective electromechanical coupling factor $k_{cff}\;=\;0.24$ and mechanical quality factor Qm=628 were obtained.

• Transactions of Materials Processing
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• v.19 no.2
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• pp.113-119
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• 2010

Hydroforming is the technology that utilizes hydraulic pressure to form tube or sheet materials into desired shapes inside die cavities. Tube hydroforming provides a number of advantages over the conventional stamping process, including fewer secondary operations, weight reduction, assembly simplification, adaptability to forming of complex structural components and improved structural strength. In many case, hydroformed parts have to be structurally joined at some point. Therefore it is useful if the hydroformed automotive parts can be given a localized attachment flange. In this study for the numerical process design FE analysis was performed with DYNAFORM 5.5. Die parting angle and circumferential expansion ratio was optimized. With optimized condition, bulge and hydroforming experiments to form flange were performed. Forming characteristic at various pressure conditions was analyzed and optimized internal pressure condition was evaluated. The results show that flanged parts can be successfully produced by tube hydroforming process.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.10
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• pp.941-948
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• 2017

Recently, hydrogen energy has been in the spotlight as an alternative to diminishing fossil fuels and as a potential solution to environmental pollution. The development of hydrogen-fueled vehicles and the demands for improved fuel efficiencies have resulted in the need to increase the volume of the hydrogen pressure vessels. Pressure vessels having an elliptical bottom, as opposed to one that is hemispherical, allow for a greater capacity. However, there are insufficient studies on the feasibility of the forming process required for an elliptical bottom. In this study, the liner capacity is calculated according to the ratios of the major to the minor axes of the elliptical bottom part in a hydrogen pressure vessel. Structural safety is verified through finite element analyses, and the results are compared to the theoretical results. The feasibility of the proposed elliptical shape of the pressure vessel bottom, while filled to maximum capacity, is validated through forming analysis.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.21-24
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• 2003

In hot forming process of the backward end-bulkhead of a pressure hull, the blank diameter and the tool clearance are the critical factors which influence wrinkling defect, forming load and shape completeness of the product. Two F.E.A softwares with the elasto-plastic material model and rigid plastic model were utilized to predict the occurrence of wrinkling defect. Tool clearance was determined by considering the increase of blank thickness, die strength and the stretching effect. Heat treatment condition after the hot forming to recover the original properties of the material was estabilished by specimen-based heat treating experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03b
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• pp.7-15
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• 1996

A Manufacturing process of the power steering worm blank is analyzed by FEM aimulation. The process includes mainly three operations such as indentation, extrusion, and upsetting, which was designed bya forming equipment expert. The results of simulation are summarized in terms of load-stroke relationships, die pressure distributions, effective strain distribution, and deforming patterns for each forming operation. Also, Efforts are focused to get the reason that the tool expert designed the forming process in three operations. The results of the simulation are to be useful for the next advanced process planning in terms of good dimesional accuracy, savings in material and machining, no deforaming defects and imporvements in mechanical properties.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.145-147
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• 2009

The benefits of hydroforming technology are known as weight and cost savings through part consolidation and reduced post-forming processes such as welding and piercing. Hydroforming technology has some weaknesses in terms of process cycle times. But, as the hydraulic system and process designs are continuously developed, the cycle time is also reduced to acceptable and competitive levels. Hot air bulging is one of recently developed hydroforming techniques. Hot air bulging in order to further extend the forming degrees of Al lightweight material is investigated. A heated tube is placed in a heated die and sealed at the ends by sealing cylinders. The tube is subsequently expanded against the die cavity wall by internal pressure provided by air medium. The result of this study shows that axial feeding speed and air pressure have an effect on formability of Al air bulging at elevated temperature.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.116-119
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• 2007

The application of light weight materials, such as aluminum alloy, has been limited due of their poor formability. Especially, aluminum alloy tube has limited expansion capability at most 15% at room temperature. New manufacturing process, called hot air forming, is introduced to apply aluminum tube to the automotive suspension components which have complex shape and require high expansion ratio about 40%. The process is carried out at the elevated temperature above $500^{\circ}C$, so numerous material properties and process parameters related to the high temperature should be investigated and determined to get a sound product. In this study, the effect of thermal properties and forming parameters such as the temperature of tool, axial feeding and gas pressure are analyzed by using explicit finite element method.