• The KIPS Transactions:PartD
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• 제10D권7호
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• pp.1145-1148
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• 2003

We show the mixed finite element method which induces solutions that has the same order of errors for both the gradient of the solution and the solution itself. The technique to construct an efficient reusable matrix is suggested. Two families of mixed finite element methods are introduced with an automatic generating technique for matrix with my order of basis. The generated matrix by this technique has more accurate values and is a sparse matrix. This new technique is applied to solve a minimal surface problem.

• Transactions of Materials Processing
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• 제4권3호
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• pp.214-221
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• 1995

In the paper, we have proposed a new method to determine the initial billet for the forged products using a function approximation in the neural network. The architecture of neural network is a three-layer neural network and the back propagation algorithm is employed to train the network. By utilizing the ability of function approximation of a neural network, an optimal billet is determined by applying the nonlinear mathematical relationship between the aspect ratios in the initial billet and the final products. The amount of incomplete filling in the die is measured by the rigid-plastic finite element method. The neural network is trained with the initial billet aspect ratios and those of the unfilled volumes. After learning, the system is able to predict the filling regions which are exactly the same or slightly different to the results of finite element simulation. This new method is applied to find the optimal billet size for the plane strain rib-web product in cold forging. This would reduce the number of finite element simulation for determining the optimal billet size of forging product, further it is usefully adapted to physical modeling for the forging design.

• Transactions of Materials Processing
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• 제9권4호
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• pp.362-371
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• 2000

In order to reduce weight of a high-speed railroad vehicle, the main body has been manufactured by hollow section extrusion using aluminum alloys. A porthole die has utilized for the hollow section extrusion process, which causes complicated die geometry and flow characteristics. Design of porthole die is very difficult due to such a complexity. The three-dimensional finite element analysis for hollow section is also an arduous job from the viewpoint of appropriate mesh construction and tremendous computation time. In the present work, mismatching refinement, an efficient domain decomposition method with different mesh density for each subdomain, is implemented for the analysis of the hollow section extrusion process. In addition, a modified grid-based approach with the surface element layer is utilized lot three-dimensional mesh generation of a complicated shape with hexahedral elements. The effects of porthole design are discussed through the simulation for extrusion of an underframe part of a railroad vehicle. An experiment has also been carried out for the comparison. Comparing the velocity distribution at the outlet with the thickness variation of the extruded part, it is concluded that the analysis results can provide reliable measures whether the die design is acceptable to obtain uniform part thickness. The analysis results are then successfully reflected on the industrial porthole die design.

• Transactions of Materials Processing
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• 제15권3호
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• pp.232-240
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• 2006

Magnesium alloys are expected to be widely used fur the parts of structural and electronic appliances due to their lightweight and EMI shielding characteristics. While the die casting has been mainly used to manufacture the parts from the magnesium alloys, the press forming is considered as an alternative to the die casting for saving the manufacturing cost and improving the structural strength of the magnesium alloy parts. However, the magnesium alloy has low formability at room temperature and therefore, in many cases, forming at elevated temperatures is necessary to obtain the required material flow without failure. In the present study, square cup deep drawing tests using the magnesium alloy AZ31 sheet were experimentally conducted at various elevated temperatures as well as room temperature, and the corresponding finite-element simulations, which calculated the damage evolution based on the Oyane's criterion, were conducted using the stress-strain relations from the tensile tests at various temperatures. The formability predictability by the finite-element analysis was investigated by comparing the predicted damage distributions over the deformed AZ31 sheet at elevated temperatures with the corresponding experimental deformations with failures.

• Computational Structural Engineering
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• 제4권1호
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• pp.95-108
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• 1991

An explicit finite element method can be executed more rapidly and effectively on vector computer than on the scalar computer because it has suitable structures for vector processing. In this paper, an efficient vectorization method of the explicit finite element program on the memory-to-memory type vector computer is proposed. First, the general vectorization method which can be applied regardless of the vector architecture is investigated, then the method which is suitable for the memory-to-memory type vector computer is proposed. To illustrate the usefulness of the proposed vectorization method, DYNA3D, the existing explicit finite element program, is migrated on HDS AS/XL V50 which is the memory-to-memory type vector computer. Performance results on actual test show a vector/scalar speedup is above 2.4.

• Transactions of Materials Processing
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• 제21권4호
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• pp.234-239
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• 2012

This study examines the forming properties and forming loads needed to increase the edge thickness on the external face of a plate using finite element analysis(FEA). Recently, forming optimization techniques within FEA are being extensively used in designing the optimal forming conditions for processes like forging, extrusion, rolling, and spinning. Most of these existing forming operations involve reducing the volume per unit length, but research for increasing volume per unit length is not very extensive. For this study we chose an automotive engine flywheel which is a welded assembly of a plate and a gear with each component having a different thickness. We considered a forming technique to increase the thickness in order to allow the machining of the gear directly on the external face of plate alleviating the need for a weld. To study various forming techniques, we used the finite element method with the flow stress of material and incremental forming steps. We conclude from this study that the analysis of forming properties and forming loads by using the finite element analysis and testing is useful as a method to increase the thickness per unit length.

• Transactions of Materials Processing
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• 제29권6호
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• pp.362-369
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• 2020

In this study, elastoplastic finite element analysis with multi-body treatment was used to elucidate the mechanical phenomena occurring from pre-stressing of die-system. A finite element analysis model with detailed conditions is proposed. The effects of die pre-stressing slope on the circumferential components of the pre-stressed die inserts were evaluated. The role of tight fitting between the supporter and die case was also emphasized because it has a significant effect on the undesirable change in the target slope of machined inner surface of the die case around the die insert. The two mechanical problems include the one between die-insert and die case and the other between supporter and die case, and their correlation is minimized to establish the optimum design in the die structural design stage because it cannot be quantitatively controlled owing to various factors affecting the die structural behavior during die pre-stressing.

• Transactions of Materials Processing
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• 제30권6호
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• pp.275-283
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• 2021

A parametric study was conducted on the effects of five fundamental design parameters on springback, including die clearance, step height, step width, punch radius, and taper relief in an L-bending process, controlled by the compression force. The experiment was also conducted to verify the usefulness of the parametric study procedure for process design, as well as the finite element predictions. The elastoplastic finite element method was utilized. The L-bending process of the york product, which is a key part of the breaker mechanism, was employed. The deformation of the material was assumed to be due to plane strain. Five samples of each design parameter were selected based on experiences in terms of process design. The finite element predictions were analyzed in detail to show a shortcut towards the process design improvement which can replace the traditional process design procedure relying on trial-and-errors. The improved process design was verified to meet all the requirements and the predictions and experiments were in good agreement.

• Transactions of Materials Processing
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• 제31권5호
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• pp.261-266
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• 2022

To reduce the weight of the vehicle, the application of the high strength steel sheets to chassis parts is increased. High forming load is induced during the shearing process of steel chassis parts made of high strength steel, and the possibility of an eccentric load is increased depending on the product seating condition on the die, which decreases the stability and lifespan of the die. In this paper, a three-dimensional finite element analysis with the continuum element was conducted using the damage theory for the cam-trimming process of the front lower arm. The structural analysis of the trimming die was performed with the forming load result obtained from the analysis, and the amount of deflection and the stress distribution of the die during the shearing process were evaluated for the confirmation of the tool stability. The shape of the weak region of the die was modified according to structural analysis and then the stability was confirmed with the finite element analysis. The analysis result showed that the possibility of tool failure during cam-trimming process was remarkably reduced, and the reliability of the proposed modified design was validated.

• Transactions of Materials Processing
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• 제31권4호
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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.