• Transactions of Materials Processing
• /
• v.22 no.8
• /
• pp.463-469
• /
• 2013

In the previous work, a new forging process design, which included incremental upsetting, diffusion bonding and cogging, was suggested as a method to manufacture 1.9wt%C ultrahigh carbon workrolls. The previous study showed that incremental upsetting and diffusion bonding are effective in closing voids and healing of the closed void. In addition, compression tests of the 1.9wt%C ultrahigh carbon steel revealed that new microvoids form within the blocky cementite at temperatures of less than $900^{\circ}C$ and that local melting can occur at temperatures over $1120^{\circ}C$. Thus, the forging temperature should be controlled between 900 and $1120^{\circ}C$. Based on these results, incremental upsetting and diffusion bonding were used to check whether they are effective in closing and healing voids in a 1.9wt%C ultrahigh carbon steel. The incremental upsetting and diffusion bonding were performed using sub-sized specimens of 1.9wt%C ultrahigh carbon steel. The specimen was deformed only in the radial direction during the incremental upsetting until the reduction ratio reached about 45~50%. After deformation the specimens were kept at $1100^{\circ}C$ for the 1 hour in order to obtain a high bonding strength for the closed void. Finally, microstructural observations and tensile tests were conducted to investigate void closure behavior and bonding strength.

• Transactions of Materials Processing
• /
• v.22 no.5
• /
• pp.269-274
• /
• 2013

Experiments and numerical simulations of the incremental upsetting test were carried out to investigate void closure behavior and mechanical characteristic of a 1.5wt%C ultra-high carbon steel. The experimental results showed that the voids become quickly smaller as the reduction ratio increases. The simulation results confirmed this behavior and indicated that the voids were completely closed at a reduction ratio of about 40~45% during incremental upsetting. After the completion of the incremental upsetting tests, the process of diffusion bonding was employed to heal the closed voids in the deformed specimens. To check the appropriate temperature for diffusion bonding, deformed specimens were kept at 800, 900, 1000 and $1100^{\circ}C$ for an hour. In order to investigate the effect of holding time for diffusion bonding at $1100^{\circ}C$, specimens were kept at 10, 20, 30, 40, 50 and 60minutes in the furnace. A distinction between closed and healed voids was clearly established using microstructural observations. In addition, subsequent tensile tests demonstrated that complete healing of a closed void was achieved for diffusion bonding temperatures in the range $900{\sim}1100^{\circ}C$ with a holding time larger than 1 hour.

• Transactions of Materials Processing
• /
• v.4 no.2
• /
• pp.131-140
• /
• 1995

In this paper damage propagation of a material during forming is investigated with the concept of continuum damage mechanics. An isotropic damage model based on the theory of materials of type N is adopted to describe the damage process of a ductile material with large elasto-viscoplastic deformation. The stiffness degradation of the loaded material is chosen as a damage measure. The highly nonlinear equilibrium equations are reduced to the incremental weak form and approximated by the total Lagrangian finite element method. To simulate contact condition, extended interior penalty method with modified coulomb friction law is adopted. The displacement control method along with the modified Riks' continuation technique is used to solve the incremental iterative equations. As numerical examples, upsetting problem and backward extrusion problem are simulated and the results of damage propagation and $J_2$ stress contours with and without friction are presented.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2013.05a
• /
• pp.1535-1536
• /
• 2013

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2009.06a
• /
• pp.129-130
• /
• 2009

• Journal of Advanced Marine Engineering and Technology
• /
• v.18 no.4
• /
• pp.69-76
• /
• 1994

Thermal elasto-plastic analysis of axi-symmetric body by the finite element method is presented in this paper for analyzing the process of upset forming of circular section extruded bar. The example of calculation for upset forming of Nimonic extruded bar is also presented. It is shown that remeshing of quadrilateral finite element is necessary because the very highly distorted element by plastic deformation disturbs the calculation. Calculated values for nodal points in new mesh are obtained from nodal points of old mesh by linear interpolation method. The experimental results are compared with calculated values. The appearance of upsetupset forming obtained by experimental method is very similar to that obtained by calculations. So, it is proved that the thermal elasto-plastic analysis of axi-symmetric body by the finite element method is very useful for finding the optimum upsetting condition.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.14 no.5
• /
• pp.1166-1180
• /
• 1990

The study is concerned with the two-dimensional thermo-viscoplastic finite element analysis for radial forging as an incremental forging process. The deformation and temperature distribution of the workpiece during radial forging are studied. The analysis of deformation and the analysis of heat transfer are carried out for simple upsetting of cylinder by decoupling the above two analyses. A method of treatment for heat transfer through the contact region between the die and the workpiece is suggested, in which remeshing of the die elements is not necessary. Radial forging of a mild steel cylinder at the elevated temperature is subjected to the decoupled finite element analysis as well as to the experiment. The computed results in deformation, load and temperature distribution are found to be in good agreement with the experimental observations. As an example of viscoplastic decoupled analysis of hot radial forging, forging of a square section into a circular section is treated. The stresses, strains, strain rates and temperature distribution are computed by superposing material properties as the workpiece is rotated and forged incrementally. It was been thus shown that proposed method of analysis can be effectively applied to the hot radial forging processes.

• Computers and Concrete
• /
• v.8 no.4
• /
• pp.371-388
• /
• 2011

In this paper, time-continuous constitutive equations for strain rate-dependent materials are presented first, among which those for the overstress and the consistency viscoplastic models are considered. By allowing the stress states to be outside the yield surface, the overstress viscoplastic model directly defines the flow rule for viscoplastic strain rate. In comparison, a rate-dependent yield surface is defined in the consistency viscoplastic model, so that the standard Kuhn-Tucker loading/unloading condition still remains true for rate-dependent plasticity. Based on the formulation of the consistency viscoplasticity, a computational elasto-viscoplastic constitutive model is proposed for the short fiber-reinforced fresh cementitious paste for extrusion purpose. The proposed constitutive model adopts the von-Mises yield criterion, the associated flow rule and nonlinear strain rate-hardening law. It is found that the predicted flow stresses of the extrudable fresh cementitious paste agree well with experimental results. The rate-form constitutive equations are then integrated into an incremental formulation, which is implemented into a numerical framework based on ANSYS/LS-DYNA finite element code. Then, a series of upsetting and ram extrusion processes are simulated. It is found that the predicted forming load-time data are in good agreement with experimental results, suggesting that the proposed constitutive model could describe the elasto-viscoplastic behavior of the short fiber-reinforced extrudable fresh cementitious paste.