• Transactions of Materials Processing
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• v.14 no.8 s.80
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• pp.675-680
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• 2005

This study was aimed at the design of the dies for the automobile part for the engine oil leakage prevention using the computer simulation to shorten the period of production, on the basis of the process planning which was designed by the field experts. In the computer simulation,'eesy-2-form' of 2D FEM simulation package and 'eesy-DieOpt' have been used, which are the commercial process analysis and die design program. Through the simulation of 'eesy-2-form', we could know the propriety of the forming process, the inner pressure of the die and the suitable fitting pressure between the insert and the sleeve which was not showing any positive tangential stresses in the insert. Through the simulation of 'eesy-DieOpt', we could know the number of the stress ring, the diameter ratios, the stresses of the die, the shrink fitting tolerance and temperature in the condition of the already determined maximum outer die diameter of the multi-stage former. The validity of the die design using the computer simulation was analyzed by the experiments and the results were satisfactory. As the results of this study, the new and easy die design system for cold forging has been developed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.361-363
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• 2007

The light weight aluminum subframe for automobile chassis part was developed using hybrid process, i.e. extruforming, press stamping and MIG welding. To achieve a 30 % weight reduction compared with conventional steel subframe keeping satisfactory performance, the design of cross-section of extruforming part was introduced, then forming simulation was performed and the final design was determined. In addition, we tried to estibilish optimun aluminum welding conditions for good penetration depth and few pore defact, finally the prototype of aluminum subframe was assembled using MIG welding method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.11a
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• pp.1-12
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• 2001

In cold forging of piston-pin for automobile parts, the flow defect appears by the dead metal zone. This appearance evidently happens in products with a thin piercing thickness for the dimension accuracy and the decrease of material loss. The best method that can prevent flow defect is removing dead metal zone. The purpose of this study is to investigate the material flow behavior of forward-backward extruded piston-pin through the relative velocity ratio and the stroke control of upper moving punch & container using the flow control forming technique. The finite element simulations are applied to analyse the flow defect, then the results are compared with the plasticine model material experiments. Finally, the model experiment results are in good agreement with the FE simulation ones.

• Transactions of Materials Processing
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• v.11 no.1
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• pp.54-60
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• 2002

The purpose of the present paper is to investigate the effect of Process parameters such as internal pressure, amount of axial feeding, and frictional condition between the die and the material on the tube hydro-formability. For carbon steel tubes(STKM 12A, STBH 410 and SPS 290), simple bulging, circular bulging and Tee-fitting tests are performed to evaluate the hydro-formability of these materials which is determined by deformation characteristics such as thickness distribution, forming height and branch dome shape. The formabilities obtained from these tests are analysed and compared with the results of the numerical simulation.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.347-355
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• 1999

The paper is concerned with an improved scheme for application of the blank holding force in order to take account of the thickness distribution in the sheet material of the flange region. The scheme incorporates with a modified membrane finite element method for planar anisotropic materials. The new scheme proposed two coefficients α and βto calculate the compressive stress in the sheet metal due to the blank holding force, which should be determined properly for accurate analysis. The effect of αand βon the blank holding force distribution and the deformed shape is investigated with simulation of rectangular cup deep drawing processes by changing parameter values.

• Transactions of the Korean Society of Automotive Engineers
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• v.4 no.6
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• pp.27-38
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• 1996

A two-dimensional FEM program, which considers bending effects in the membrane fromulation, was developed under plane strain assumption for analyzing forming processes of an arbitrarily shaped draw-die of automotive panels. For the evaluation of bending effects with membrane elements, the bending equivalent forces and stiffnesses are calculated from the bending moment computed using the changes in curvature of the formed shape of two membrane ones. The curves depicted with 3 nodes are described by a circle, a quadratic equation, and a cubic equation, respectively, and in the simulation of the stretch/draw sections of an automotive inner panel, three different description results are compared each other. Also, the bending results are compared with membrane results and measurements in order to verify the validity of the developed program.

• Proceedings of the KIPE Conference
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• 2001.10a
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• pp.132-135
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• 2001

The design of square pulse generators using pulse forming lines (PFLs) made up of identical L and C, was reviewed in this study. 14 different types of PFLs were analyzed utilizing PSpice simulation results. These PFLs were characterized with respect to their distinct features: the number of forming lines (single or double), the circuit relationship between PFL and load (parallel or series), the types of energy storage (voltage source, current source or a combination of both). The characteristic impedances, output parameters such as pulse width, voltage and current magnitudes, and powers were derived for each scheme. The merits and demerits of the output parameters were also included.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.2
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• pp.60-66
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• 2004

Finite element method is very effective method to simulate the forming processes with good prediction of the deformation behaviour. In this paper, It was focussed on the drawability factors on the square cup deep drawing by PAM-STAMP with using magnesium alloy to reduce car weight as well as to draw much attention from the viewpoint of environmental preservation high rigidity, In order to predict the effect of drawability factors, the relationships between punch load and punch stroke, the relationships between thickness strain and distance, and are used. According to this study, the results of simulation will give engineers good information to access the drawability of square cup deep drawing at warm temperature.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.124-128
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• 2004

By the use of a similar numerical method as that in the previous paper, the forming limit strain by coaling method of clad sheet metals is investigated, in which the FEM is applied and J2G(J$_2$-Gotoh's corner theory) is utilized as the plasticity constitutive equation. Declined Multilayer Metals Materials are stretched in a plane-strain state, with various work-hardening exponent n-values and thicknesses of each layer. Processes of shear-band formation in such composite sheets are clearly illustrated. It is concluded that, in the bonded state, the higher limiting strain of one layer is reduced due to the lower limiting strain of the other layer and vice versa, and does not necessarily obey the rule of linear combination of the limiting strain of each layer weighted according thickness.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.10a
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• pp.212-217
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• 1993

A 2-dimensional FEM/GEM program was developed for analyzing forming processes of an arbitrarily shaped draw-die, in which plane strain condition is assumed and linear line elements are employed. FEM formulation adopted a new algorithm for solving force equilibrium as well as non-penetration condition simultaneously. For the case of numerical divergence at nearly final forming stages and the initial guess in Newton-Raphson iterations, geometric force equilibrium method(GEM) is also introduced. The developed program was tested with the simulation of stamping processes of automotive bonnet inner pannel in order to verify the usefulness and validity of FEM/GEM formulation.