• Transactions of Materials Processing
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• v.17 no.3
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• pp.189-196
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• 2008

Alloy718 is the nickel-base super alloy well used as gas turbine components under severe operating conditions because of its high strength at high temperature and excellent creep resistance. In this study, a coupling bolt for the gas turbine component is manufactured by hot heading process instead of whole machining in order to improve the mechanical properties. Die shape for the hot heading has been designed by general design rule of hot forging and also optimal process condition has been investigated by finite element method. The initial billet temperature and the punch speed have been determined by $1150^{\circ}C$ and 600mm/s on the basis of finite element analysis, respectively. The coupling bolt has been manufactured by 200ton screw press and evaluated by experiment in order to investigate the mechanical properties. As a result of experiment, the mechanical properties such as hardness, tensile strength and creep behavior have been superior to those manufactured by machining.

• Transactions of Materials Processing
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• v.1 no.1
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• pp.66-74
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• 1992

According to the variation of hydrostatic pressure on the central axis of deformable material, the V-shaped central bursting defect may be created in extrusion or drawing processes. The process factors which affect the generation of defects are semi-angle of die, reduction ratio of cross-sectional area, friction factor, material properties and so on. The combination of these factors can determine the possibility of defect creation and the shape of various round holes which have been created inside already. By the rigid plastic finite element method, this paper describes the observations of change in shape of round holes with process conditions such as semi-angle of die, reduction ratio of cross-sectional area and friction factor at the non-steady state of axisymmetrical extrusion process when the round hole is already existed inside the original billet. Also, the effects of process factors are investigated to prevent the possible defects.

• Transactions of Materials Processing
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• v.17 no.1
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• pp.52-58
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• 2008

Tube hydroforming process is generally consisted with pre-bending, preforming and hydroforming processes. Among forming defects which may occur in tube hydroforming such as buckling, wrinkling and bursting, the wrinkling and bursting by local instability under excessive tensile stress mode were mainly caused by thinning phenomenon in the manufacturing process. Thus the accurate prediction and suitable evaluation of the thinning phenomenon play an important role in designing and producing the successfully hydroformed parts without any failures. In this work, the formability on hydroformed part for automobile, i.e. engine cradle, was evaluated using finite element analysis. The initial tube radius, loading path with axial feeding force and internal pressure, and preformed configuration after preforming process were considered as the dominant process parameters in total tube hydroforming process. The effects on these process parameters could be confirmed through the numerical experiments with respect to several kinds of finite element simulation conditions. The degree of enhancement on formability with each process parameters such as initial tube radius, loading path and preform configuration were also compared. Therefore, it is noted that the evaluation approach of the formability on hydroformed parts for lots of industrial fields proposed in this study will provide one of feasible methods to satisfy the increasing practical demands for the improvement of the formability in tube hydroforming processes.

• Transactions of Materials Processing
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• v.16 no.3 s.93
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• pp.187-192
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• 2007

The finite volume method for forging simulation is examined to reveal its possibility as well as its problem in this paper. For this study, the finite volume method based MSC/SuperForge and the finite element method based AFDEX are employed. The simulated results of the homogeneous compression obtained by the two softwares are compared to indicate the problems of the finite volume method while several application examples are given to show the possibility of the finite volume method fur simulation of complex hot forging processes. It is shown that the finite volume method can not predict the exact solution of the homogeneous compression especially in terms of forming load and deformed shape but that it is helpful to simulate very complex forging processes which can hardly be simulated by the conventional finite element method.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.600-606
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• 2008

In closed-die hot forging, a billet is formed in dies such that the flow of metal from the die cavity is restricted. Some parts can be forged in a single set of dies, whilst others, due to shape complexity and material flow limitations, must be shaped in multi sets of dies. The purpose of a performing operation is to distribute the volume of the parts such that material flow in the finisher dies will be sound. This study focused on the design of preforms, flash thickness and land width by theoretical calculation and finite element analysis, to manufacture the super hot forging product, 70MC type piston crown used in marine engine. The optimal design of preforms by the finite element analysis and the design experiment achieves adequate metal distribution without any defects and guarantees the minimum forming load and fully filling of the cavity of the die for producing the large piston crown. The maximum loads obtained by finite element analysis are compared with the results of experiments. The loads of the analysis have good agreements with those of the experiment. Results obtained using DEFORM-2D enable the designer and manufacturer of super hot forging dies to be more efficient in this field.

• Transactions of Materials Processing
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• v.20 no.6
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• pp.450-455
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• 2011

This paper presents an inverse design methodology for the cross section geometry of mold spring with a rectangular cross section as the starting material for a coiling process. The cross-sections of mold springs are universally rectangular, as the parallel sides minimize the possibility of failure under high service loads. Pre-coiled wires are initially designed to have a trapezoidal cross section, which becomes a rectangle by the coiling process. This study demonstrates a numerical exercise to predict changes in the sectional geometry in spring manufacture and to obtain the initial cross section which becomes the exact rectangle desired from the manufacturing process. Finite element analysis was carried out to calculate the sectional changes for various mold springs. Geometrical parameters were the widths at inner and outer radii, the inner and the outer corner radii, and the height. A partial least square regression analysis was carried out to find the main contributing factors for deciding initial design values. The height and the width mainly affected various initial parameters. The initial width at the inner radius was mostly affected by various specification parameters.

• Transactions of Materials Processing
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• v.26 no.5
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• pp.286-292
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• 2017

Magnesium alloy shows strong anisotropy and asymmetric behavior in tension and compression curve, especially at room temperature. These characteristics limit the application of finite element method (FEM) which is based on conventional continuum mechanics. To accurately predict the material behavior of magnesium alloy at microstructural level, a methodology of fully coupled multiscale simulation is presented and a crystal plasticity model as a constitutive equation in the simulation of metal forming process is introduced in this study. The existing constitutive equation for rigid plastic FEM is modified to accommodate deviatoric stress component and its derivatives with respect to strain rate components. Viscoplastic self-consistent (VPSC) polycrystal model was selected as a constitutive model because it was regarded as the most robust model compared to Taylor model or Sachs model. Stiffness matrix and load vector were derived based on the new approach and implemented into $DEFORM^{TM}-3D$ via a user subroutine handling stiffness matrix at an elemental level. The application to extrusion and rolling process of pure magnesium is presented in this study to assess the validity of the proposed multiscale process.

• Transactions of Materials Processing
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• v.26 no.4
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• pp.210-215
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• 2017

In this paper, utilizing the theory of ductile fracture a chevron crack in a 4-stage open cold extrusion process is predicted by the finite element methods and then compared with previous experiments. The normalized Cockcroft-Latham damage model is employed and the material is identified using a tensile test based material identification technique that gives fracture information as well as flow stress at large strain. A large difference between the predicted cracks and actual experiments is observed, specifically narrower width and greater maximum height of the crack. This reveals the limitation of this approach based on the conventional theory of ductile fracture. Based on the observations and the related criticisms, a new approach for predicting the chevron crack is proposed, suggesting that either the critical damage should not be a fixed material constant, or that the conventional fracture theory should be considered with the effects of embrittlement due to accumulated plastic deformation while the duration of crack generation and plastic deformation should be reduced.

• Journal of the Korea Institute of Information and Communication Engineering
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• v.14 no.12
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• pp.2798-2804
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• 2010

The audio and image signal are corrupted by various noises in signal processing, many studies are being accomplished to restore those signals. In this paper, the algorithm is proposed to remove additive Gaussian noise and impulse noise at one dimension signal like an speech signal. The algorithm is composed to remove Gaussian noise after removing impulse noise. And the method using wavelet coefficient accumulation is used to remove the Gaussian noise, and the median filter based on element deviation is applied to remove the impulse noise. Also we compare existing methods using SNR(signal-to-noise ratio) as the standard of judgement of improvemental effect.

• Smart Structures and Systems
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• v.12 no.5
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• pp.579-594
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• 2013

A new enthalpy - based procedure for the homogenization of the electromechanical material parameters of composite piezoelectric modules with integrated electrodes is presented. It is based on a finite element (FE) modeling of the latter's representative volume element (RVE). In contrast to most previously published homogenization approaches that are based on averaged quantities, the presented method uses a direct evaluation of the electromechanical enthalpy. Hence, for the linear orthotropic piezoelectric composite behavior full set of elastic, piezoelectric, and dielectric material parameters, 17 load cases (LC) are used where each load case leads directly to one material parameter. This gives the possibility to elaborate a very strict and easy to program processing. In conjunction with the 17 LC, the enthalpy - based homogenization is particularly suitable for laminated composite piezoelectric modules with integrated electrodes. In this case, the electric load has to be given at the electrodes rather than at the RVE FE model boundaries. The proposed procedure is validated through its comparison to literature available results on a classical 1-3 piezoelectric micro fiber (longitudinally polarized) reinforced composite and a $d_{15}$ shear piezoelectric macro-fiber (transversely polarized) composite module.