• KSCE Journal of Civil and Environmental Engineering Research
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• v.11 no.1
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• pp.17-27
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• 1991

The determination of the stress intensity factors is investigated by means of a surface integral defined around the crack tip of the structure. It has been shown in this work that this integral is derived from the standard path integral J. The use of the surface integral has also been extended to the case where body forces act. Computer program obtaining the stress intensity factors $K_I$ and $K_{II}$ is developed, which prepares input variables from the result of the conventional finite element analysis. This paper provides a parabolic smooth curve function. By the use of the function and conventional element meshes in which the aspect ratio (element length/crack length)is about 25 percent, relatively correct $K_I$ and $K_{II}$ values can be obtained for the exterior radius ranging from 1/3 to 1 of the crack length.

• Transactions of Materials Processing
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• v.14 no.5 s.77
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• pp.423-431
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• 2005

In this paper, a systematic attempt for estimating geometric dimensions of cold forgings is made by finite element method and a practical approach is presented. In the approach, the forging process is simulated by a rigid-plastic finite element method under the assumption that the die is rigid. With the information obtained from the forging simulation, die structural analysis and springback analysis of the material are carried out. In the springback analysis, both mechanical load and thermal load are considered. The mechanical load is applied by unloading the forming load elastically and the thermal load is by cooling the increased temperature due to the plastic work to the room temperature. All the results are added to predict the final dimensions of the cold forged product. The predicted dimensions are compared with the experiments. The comparison has revealed that predicted results are acceptable in the application sense.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.10
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• pp.84-91
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• 2008

Due to the complexity of the engineering problems, it is difficult to obtain directly the stress field around the crack tip by theoretical derivation. In the paper, the hybrid method is employed to calculate full-field stress around the crack tip in uni-axially leaded finite width tensile plate, using the displacement data of given points calculated by finite element method as input data. The method uses complex variable formulations involving conformal mappings and analytical continuity. In order to accurately compare calculated fringes with experimental ones, both actual and reconstructed photoelastic fringe patterns are two times multiplied and sharpened by digital image processing. Reconstructed fringes by hybrid method are quite comparable to actual fringes. The experimental results indicate that Mode I stress intensity factor analyzed by the hybrid method are accurate within a few percent compared with ones obtained by empirical equation and finite element analysis.

• Transactions of Materials Processing
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• v.19 no.8
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• pp.447-451
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• 2010

In this paper, a useful die system for warm plate forging of a large axle housing of heavy-duty trucks is presented. A die system composed of material flow guide pin as well as upper die and lower die is proposed to reduce the inherent thickness reduction along the bent corner of the product which deteriorates structural strength and fatigue life in its service. The role of the pin assembled in the upper die is to prevent formation of sharp corner in early forming stage and to supply material in the lower die cavity sufficient enough to thicken the bent corner at the final stroke. The mechanism of the die system is given and its effect on corner thickness of the product is revealed by two-dimensional finite element analysis under plain strain assumption. Three-dimensional finite element solutions are also given to verify validity of the two dimensional approach and to show the mechanics of the die system in detail. The die system has been successfully applied to manufacturing the axle housing of heavy-duty trucks.

• Transactions of Materials Processing
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• v.19 no.3
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• pp.152-159
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• 2010

Rapid mold heating has been recent issue to enable the injection molding of thin-walled parts or micro/nano structures. High-frequency induction is an efficient way to heat mold surface by electromagnetic induction in a non-contact manner, and has been recently applied to the injection molding due to its capability of rapid heating and cooling of mold surface. The present study covers a three-dimensional finite element analysis to investigate heating efficiency and structural safety of the induction heating process of an injection mold. To simulate the induction heating process, an integrated simulation method is proposed by effectively connecting an electromagnetic field analysis, a transient heat transfer analysis and a thermal stress analysis. The estimated temperature changes are compared with experimental measurements for various types of induction coil, from which heating efficiency according to the coil shape is discussed. The resulting thermal stress distributions of the mold plate for various types of induction coils are also evaluated and discussed in terms of the structural safety.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.11
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• pp.2954-2966
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• 1994

The characteristics and good corrosion resistance at room and elevated temperatures led to increasing application of Ti-alloys such as aircraft, jet engine, turbine wheels. In forging of Ti-alloy at high temperature, die chilling and die speed should be carefully controlled because the flow stress of Ti-alloy is sensitive to temperature, strain and strain-rate. In this study, the forging of turbine disk was numerically simulated by the finite element method for hot-die forging process and isothermal forging process, respectively. The effects of the temperature changes, the die speed and the friction factor were examined. Also, local variation of process parameters, such as temperature, strain and strain-rate were traced during the simulation. It was shown that the isothermal forging with low friction condition produced defect-free disk under low forging load. Consequently, the simulational information will help industrial workers develope the forging of Ti-alloys including 'preform design' and 'processing condition design'. It is also expected that the simulation method can be used in CAE of near net-shape forging.

• Transactions of Materials Processing
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• v.6 no.5
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• pp.446-455
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• 1997

A Combined extrusion operation consists of forward and backward extrusion forming and it is possible to make the process be simple by employing it. But the metal flow pattern induced by the operation is hard to analyze accurately because the flows are non-steady, which have at least two directions dependent upon each other. So engineers in the industrial factories had conducted the two extrusion operations separately. A new process was designed by the industrial expert for forming of an alu-minum preform using the combined extrusion operation. In this study, experiments and finite element analysis was carried out to determine the process parameters. Through the preliminary experiment, it was shown that warm forming condition was more desirable than cold or hot ones. And optimal shape of initial billet could be also determined. From the compatibility test, bonde-lube was chosen as the optimal lubricant and 20$0^{\circ}C$ as the material temperature by the inspection of micro-structure. The operation was simulated by the rigid-plastic finite element method to examine the metal flow. Disap-pearing of dead metal zone was observed as the punch fell down and desirable shape was obtained from the one operation. As a result of this study, 7 operations could be reduced and 225% of material saved.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.359-362
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• 2006

In this paper, hole expanding tests are carried out in order to identify the effect of the hole process condition on the hole expanding ratio. Specimens with two different hole conditions are prepared: one is produced with punching process; and the other is reamed after punching to get smoother hole surface. The experimental results show that the facture mechanism and the hole expanding ratio are quite different with respect to the hole condition. The hole expanding ratio of a punched specimen is much smaller than that of a reamed one due to the difference of surface roughness and internal defects. For the thorough investigation of those effects, tensile tests of a specimen with a hole are performed. The fracture strain is obtained with different hole conditions and a finite element analysis of the hole flanging process carried out. The experimental results are confirmed and reevaluated by finite element analysis of the hole flanging process with ductile fracture criterion proposed.

• Transactions of Materials Processing
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• v.25 no.1
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• pp.29-35
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• 2016

In the current study, finite element analysis was conducted for the press hemming of automotive panels in order to predict various hemming defects such as roll-in and turn down. The analysis used the exact punch movement based on the cam location and considered the sealer between the inner and outer panels with an artificial contact thickness. The analysis results quantify the hemming defects especially at the flange edge in the matching region of the head lamp. A design of experiments along with the parameter study was used to obtain the optimum process parameters for minimizing hemming defects. The optimization process selects the intake angle, bending angle of the hemming punch, and the flange height of the outer panel. The optimum design process determines an appropriate tool angle and flange height to reduce the roll-in and turn-down as compared to the initial design.

• The Journal of Korean Institute of Communications and Information Sciences
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• v.32 no.4C
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• pp.440-446
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• 2007

This paper addresses a new representation of DFT matrix via the Jacket transform based on the element inverse processing. We simply represent the inverse of the DFT matrix following on the factorization way of the Jacket transform, and the results show that the inverse of DFT matrix is only simply related to its sparse matrix and the permutations. The decomposed DFT matrix via Jacket matrix has a strong geometric structure that exhibits a block modulating property. This means that the DFT matrix decomposed via the Jacket matrix can be interpreted as a block modulating process.