• Transactions of Materials Processing
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• v.6 no.3
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• pp.233-238
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• 1997

The estimation of the forming force required for metal forming process is unavoidable for selecting suitable machine and dimensioning die and punch parts. For this purpose the upper-bound method turns out to be very practical in simple two-dimensional cases under well-known boundary conditions. However, the application of this method for complicated two-or three-dimentional cases is very limited or practically impossible. The modified application of FEM in a manner of applying the upper bound method(the so-called Upper-bound Finite Element Simulation Method) fortunately provides the posibility of getting important information about the forming process in a simple and quick way before realizing the process on the machine. It is expected to function successfully even in three-dimentional cases. The application procedure has been explained for two-dimensional cases and its usefulness shown.

• Transactions of Materials Processing
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• v.10 no.2
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• pp.144-150
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• 2001

Tool design is introduced in a multi-stage rectangular cup drawing process with the large aspect ratio. Finite element simulation is carried out to investigate deformation mechanisms with the initial tool design. The analysis reveals that the difference of the drawing ratio and the irregular contact condition produces non-uniform metal flow to cause wrinkling and severe extension. For remedy, the modification guideline is proposed in the design of the tool and process. Analysis results confirm that the modified tool design not only improves the quality of a deep-drawn product but also reduces the possibility of failure.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.596-600
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• 2009

Finite element simulation is an alternative method to practically find the forming limit diagram(FLD). In this paper, the novel fracture criterion is utilized to predict the FLD in conjunction with finite element analysis for sheet forming. The principal scheme of the fracture criterion in this paper is that growth of the micro voids leads up to fracture in the viewpoint of micro-mechanics. The numerical FLD is verified by results of the out-of plane stretching test using hemispherical punch. The verification is also conducted about two types of material. These results are in good accord with the experimental results. Especially, the proposed scheme is appropriate to predict FLDs for a restricted material with low ductility after the instability point or ultimate tensile strength.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.3
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• pp.57-64
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• 2002

Finite element program(ANSYS) estimated thermal deformation quantity in high frequency heat treatment process of a machine tool fred drive system slideway and apply deformation quantity in roughing process. Having processed the heat treatment minimizing methods of the quantity of deformation heat treatment process. Having done heat treatment with high frequency after taper processing with considering the existed heat treatment generating the quantity of deformation, existed quantity of deformation can be reduced down to 80%, consequently productivity and material saving can be achieved. When high frequency heat treatment finite element method estimated deformation quantity at difference temperature and time, it is progress at cost don and saved time.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.305-310
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• 2008

This paper provides the methods to estimate the burst pressures of the pipes with defects, based on finite element analyses. FE codes are frequently adopted for the simulations of the burst tests of the pipes with defects. However, those do not give the burst pressure directly. Because the post-processing should be followed; determination of the fracture strains in accordance with triaxialities, monitoring the strains of pipes, etc. In the present work, these efforts are implemented in the user subroutine UHARD within the general-purpose FE code, ABAQUS. Four fracture criterions are introduced to estimate the burst pressure of pipes, and a simple fracture strain estimate is also developed. FE analyses for the pipe with gouge and corrosion are performed, and the results are compared with the experiment results.

• Transactions of Materials Processing
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• v.13 no.2
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• pp.148-153
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• 2004

Finite element analysis of open die forging process to make rectangular billet has been performed in this study. Three dimensional rigid-plastic finite element method was used to analyze the effects of process variables, forging pass design and die configurations on the void closure phenomena to maximize the internal deformation for better structural homogeneity and center-line consolidation of the rectangular billet. The effect of anvil width ratio, anvil pitch, anvil shape and number of pass has been estimated by the degree of void closure ratio. Although it is difficult to optimize process parameters in the operational environments, favourable process conditions are suggested for better product quality.

• Transactions of Materials Processing
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• v.13 no.2
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• pp.174-179
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• 2004

The effect of grain refinement on the plastic deformation behaviour of nanocrystalline metallic materials is investigated. A phase mixture model in which a single phase material is considered as an effectively two-phase one is discussed. A distinctive feature of the model is that grain boundaries are treated as a separate phase deforming by a diffusion mechanism. For the grain interior phase two concurrent mechanisms are considered: dislocation glide and mass transfer by diffusion. The proposed constitutive model was implemented into a finite element code (DEFORM) using a semicoupled approach. The finite element method was applied to simulating room temperature tensile deformation of Cu down to the nanoscale grain size in order to investigate the pre- and post-necking behaviour.

• Transactions of Materials Processing
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• v.4 no.4
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• pp.365-374
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• 1995

Numerical simulation of blade forming is carried out as stretch forming by an elasto-plastic finite element method. The method adopts a Lagrangian formulation, which incorporates large deformation and rotation, with a penalty method to treat the contact boundary condition. Numerical integration is done with a directional reduced integration scheme to avoid shear locking. The numerical results demonstrates various final shapes of blades which depend on the variation of the stretching force. The strain distributions in deformed blades are also obtained with the variation of the stretching force.

• Transactions of Materials Processing
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• v.18 no.3
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• pp.229-235
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• 2009

This paper covers finite element simulations to evaluate the terminal crimping process of automobile electrical connector. Crimping is a classical technology process to ensure the electrical and the mechanical link between a wire and a terminal. Numerical modeling of the process is helpful to choose and to optimize the dimensions of the crimping part of the connector. In this paper, we discuss a 2D simulation of the crimping process, using explicit finite element methods (ABAQUS/Explicit) and we compare the results with experimental data from the industrial process of crimping (crimping height, crimping width and compressibility). The explicit method is preferred for the modeling of multi-contact problems, in spite of the quasi-static process of crimping. As compared with CAE analysis, a performance improvement makes certain of the truth of the matter.

• Transactions of Materials Processing
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• v.20 no.8
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• pp.562-567
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• 2011

This paper deals with effects of certain important factors in a tube drawing operation, such as the use of a mandrel, die radius and tangential angle at die outlet, on the deformation behavior of a small-diameter seamless tube. Both experimental and finite element simulation studies are carried out to assess the effects of the above parameters. Experiments and finite element predictions are compared. The use of a mandrel simplifies the design of tube drawing, but also induces some difficulties from increased process complexity. The effects of die outlet tangential angle and radius are discussed in detail.