• Transactions of Materials Processing
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• v.30 no.3
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• pp.109-118
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• 2021

Recently, there has been an increased interest in the remanufacturing of mechanical parts using metal additive manufacturing processes in regards to resource recycling and carbon neutrality. DED (directed energy deposition) process can create desired metallic shapes on both even and uneven substrate via line-by-line deposition. Hence, DED process is very useful for the repair, retrofit and remanufacturing of mechanical parts with irregular damages. The objective of the current paper is to investigate the effects DED process parameters, including the effects of power and the scan speed of the laser, on deposition and residual stress characteristics for remanufacturing of mechanical parts using experiments and finite element analyses (FEAs). AISI 1045 is used as the substrate material and the feeding powder. The characteristic dimensions of the bead shape and the heat affected zone (HAZ) for different deposition conditions are obtained from the experimental results. Efficiencies of the heat flux model for different deposition conditions are estimated by the comparison of the results of FEAs with those of experiments in terms of the width and the depth of HAZ. In addition, the influence of the process parameters on residual stress distributions in the vicinity of the deposited region is investigated using the results of FEAs. Finally, a suitable deposition condition is predicted in regards to the bead formation and the residual stress.

• Transactions of Materials Processing
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• v.31 no.4
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• pp.200-206
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• 2022

The finite element analysis is one of the representative methods for predicting the materials behavior for experiments that are difficult to perform empirically. Constitutive equations are essential for reducing computation time and sharing data because they enable finite element analysis simulations through simple formulae. However, it is difficult to derive accurate flow curves for all materials as most constitutive equations are not formulated based on their physical meaning. Also, even if the constitutive equation is a good representation of the flow curve to the experimental results, some fundamental issues remain unresolved, such as the effect of mesh size on the calculation results. In this study, a new constitutive equation was proposed to predict various materials by modifying the combined Swift-Voce model, and the calculation results with various mesh sizes were compared to better simulate the experimental results.

• Transactions of Materials Processing
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• v.32 no.3
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• pp.122-128
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• 2023

As electric vehicles (EV) have increasingly replaced the conventional vehicles with internal combustion engines (ICE), most of automotive makers are actively devoting to the technology development of EV parts. Accordingly, the manufacturing process for power source has been also shifting from engine/transmission to EV motor/reducer system. However, lack of experience in developing the EV motor still remains as a technical challenge. In this paper, we employed the forming simulation based on finite element modeling to solve this problem. In particular, in order to increase the accuracy of the forming simulation, we introduced the elastic-plastic constitutive model parameters for polymer-copper hybrid wire by investigating the individual strain-stress curves, and elastic modulus of polymer and copper. Then, the reliability of modeling procedure was confirmed by comparing the simulated results with experiments. Finally, the identified mechanical properties and finite element modeling were applied to a hairpin forming process, which involves multiple deformation paths such as bending, pressing, widening, and twisting. The proposed numerical approach can replace common experience or experiment based trials by reducing production time and cost in the future.

• Geomechanics and Engineering
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• v.32 no.1
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• pp.85-96
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• 2023

Microbially induced carbonate precipitation (MICP) is extensively discussed as a promising topic for ground stabilization. The practical effect of stabilizing the expansive soil is presented in this paper with a logical process from the bacterial activity to the treatment technology. Temperature, pH, shaking frequency, and inoculation amount are discussed to evaluate the bacterial activity. The physic-mechanic properties are also evaluated to discuss the effect of the MICP process on expansive soil. Results indicate that the MICP method achieves the mitigation of expansion. The treated soil has a low proportion of fine particles (< 5 ㎛), the plasticity index significantly decreases, and strength values improve much. MICP process has a significant cementation effect on the soil matrix. Moreover, the infiltration model test presents the coating effect on the topsoil. According to the relation between the CaCO₃ content and the treatment effect, the topsoil has better treatment than the deeper soil.

• Transactions of Materials Processing
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• v.32 no.2
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• pp.92-99
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• 2023

In this study, shear fracture specimens are designed using finite element analyses for the characterization of ductile fracture criteria of metal sheets. Many recently suggested ductile fracture criteria require experimental fracture data at the shear stress states in the model parameter identification. However, it is challenging to maintain shear stress states in tension-based specimens from the initial yield to the final fracture, and the loading path can be different for the different materials even with the same shear specimen geometries. To account for this issue, two different shear fracture specimens for low ductility/high ductility metal sheets are designed using the sensitivity tests conducted by finite element simulations. Priorly mechanical properties including the Hosford-Coulomb fracture criterion of the aluminum alloy 7075-T6 and DP590 steel sheets are used in the simulations. The results show that shear stress states are well-maintained until the fracture at the fracture initiation points by optimizing the notch geometries of the shear fracture specimens.

• Transactions of Materials Processing
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• v.32 no.2
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• pp.74-80
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• 2023

A deformation behavior of commercially pure titanium (CP-Ti) is highly dependent on material and processing parameters, such as deformation temperature, deformation direction, and strain rate. This study aims to predict the multivariable and nonlinear tensile behavior of CP-Ti using machine learning based on three algorithms: artificial neural network (ANN), light gradient boosting machine (LGBM), and long short-term memory (LSTM). The predictivity for tensile behaviors at the cryogenic temperature was lower than those in the room temperature due to the larger data scattering in the train dataset used in the machine learning. Although LGBM showed the lowest value of root mean squared error, it was not the best strategy owing to the overfitting and step-function morphology different from the actual data. LSTM performed the best as it effectively learned the continuous characteristics of a flow curve as well as it spent the reduced time for machine learning, even without sufficient database and hyperparameter tuning.

• Transactions of Materials Processing
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• v.32 no.6
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• pp.321-328
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• 2023

To ensure driver safety, high-strength steel pipes are utilized in the chassis and internal structures design of automobiles. ERW(electric resistance welding) pipes, fabricated through welding at joints using electrical resistance, form a Heat-Affected Zone (HAZ) during the welding process. Due to characteristics such as increased hardness and reduced ductility compared to the base material, HAZ poses challenges in finite element analysis (FEA) for pipe shapes. In this study, for FEA considering HAZ properties, mechanical properties were measured through uniaxial tensile testing and digital image correlation (DIC) techniques after specimen fabrication. These measurements were validated using reverse engineering methods. Furthermore, hardness measurements and gaussian functions were employed to ascertain the hardness distribution within the HAZ, serving as a basis for subdividing the HAZ and modeling the pipe shape. To validate the effectiveness of the HAZ modeling approach, models were interpreted incorporating only base material properties and models incorporating average-calculated HAZ properties. Comparative analysis was performed, revealing that the model subdividing the HAZ based on hardness measurements closely approximated experimental values. This validation offered a methodology for HAZ modeling in FEA.

• Structural Engineering and Mechanics
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• v.88 no.6
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• pp.599-608
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• 2023

The present study is focused on instigation of the nonlinear mechanical behavior of reinforced concrete beams considering different types of FRP bars through nonlinear finite element simulations. To explore the impact of the FRP reinforcement type and geometry on the nonlinear mechanical behavior of reinforced beam, intensive parametric studies are carried out and discussed. Twenty models were carried out based on the finite element software (ABAQUS). The concrete damage plasticity model was considered. Four types of fiber polymer bars, CFRP, GFRP, AFRP and BFRP as longitudinal reinforcement for concrete beam were used. The validation of numerical results was confirmed by experimental as well as numerical results, then the parametric study was conducted to evaluate the effect of change in different parameters, such as bar diameter size, type of FRP bars and shear span length. All results were analyzed and discussed through, load-deflection diagram. The results showed that the use of FRP bars in rebar concrete beam improves the beam stiffness and enhance the ultimate load capacity. The load capacity enhanced in the range of (20.44-244.47%) when using different types of FRP bars. The load-carrying capacity of beams reinforced with CFRP is the highest one, beams reinforced with AFRP is higher than that reinforced with BFRP but beams reinforced with GFRP recorded the lowest load of capacity compered with other beams reinforced with FRP Bars.

• Transactions of Materials Processing
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• v.33 no.2
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• pp.112-117
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• 2024

In this study, the friction and wear characteristics of Inconel 600 in the superplastic forming process of Ti6Al4V were evaluated through pin-on-disc tests. To achieve an efficient and systematic experimental design, the Taguchi method was employed. The wear track of the Inconel 600 pin showed scratches in the sliding contact direction, confirming that the wear mechanism is abrasive wear. Through sensitivity analysis such as ANOVA and Main effects, it was confirmed that both normal force and sliding distance have a significant impact on the wear. Changes in sliding velocity and distance did not affect the friction coefficient, which remained relatively constant at approximately 0.380. The wear prediction model for Inconel 600 in the superplastic forming of Ti6Al4V was constructed, which can be utilized as a guideline for the prediction and management of tool wear.

• Transactions of Materials Processing
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• v.33 no.3
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• pp.169-177
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• 2024

Recently, hydrogen energy has been widely used because of strict regulations on greenhouse gas emissions. For using the hydrogen energy, it is required to supply hydrogen through a tube trailer. However hydrogen tube trailer can have excessive load problems during transportation due to reasons such as road shape and driving method, which may lead a risk of hydrogen leakage. So it is necessary to secure a high level of safety. The purpose of this study is to evaluate structural safety for the conservative design of hydrogen tube trailer. First, finite element(FE) modeling of the designed hydrogen tube trailer was performed. After that, safety evaluation method was established through static structural simulation based on the standard GC207 conditions. In addition, effectiveness of the designed model was confirmed through the results of the structural safety evaluation. Finally, driving simulation was used to derive acceleration graph according to time, which was considered as a dynamic property for the evaluation of conservative tube trailer safety evaluation. And dynamic structural simulation was conducted as a condition for actual transportation of tube trailer by applying dynamic properties. As a results, conservative safety was evaluated through dynamic structural simulation and the safety of hydrogen tube trailer was confirmed through satisfaction of the safety rate.