• Transactions of Materials Processing
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• v.13 no.8
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• pp.723-730
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• 2004

This paper describes the analysis of extrusion process and integrity for a condenser tube which is a component of the heat exchanger in automobile and all conditioning apparatus. Recently, according to the development of analysis method using the computer, the numerical simulation have been applied to the 3-dimensional hot extrusion process with complex section area of the non-steady statement and then results of the analysis have been applied to optimal die design and process design. In this paper, firstly, the die design was performed for a condenser tube with a multi-hole section and the rigid-plasticity FE analysis performed of extrusion process. Secondly, we estimated metal flow of billet, extrusion load, welding pressure in chamber etc. and evaluated the pressure and elastic strain of the die land and mandrel tooth profile through a stress analysis of the die. Finally, the extrusion test was performed to estimate the validity of FE analysis. This paper confirmed that the designed extrusion die of the research is satisfactorily designed fur integrity of condenser tube.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.173-176
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• 2007

The characteristics of the tool system give many effects into the costs and qualities for the finished components. This study proposes a new method for manufacturing of high manufacturing productivity, production process reduction and low cost through back pressure forming. The Lock-up hub is manufactured through many processes, such as upsetting($1^{st}$ Forming), piercing, direct extrusion($2^{nd}$ Forming), final sizing process($3^{rd}$ Forming). In this study, process design for closed-die forging of a Lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of Lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Transactions of Materials Processing
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• v.13 no.6 s.70
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• pp.540-545
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• 2004

Ever since the ideal forming theory has been developed for process design purposes, application has been limited to sheet forming and, fur bulk forming, to two-dimensional steady flow. Here, application for the non-steady case was performed under the plane-strain condition based on the theory previously developed. In the ideal flow, material elements deform following the minimum plastic work path (or mostly proportional true strain path) so that the ideal plane-stram flow can be effectively described using the two-dimensional orthogonal convective coordinate system. Besides kinematics, fur a prescribed final part shape, schemes to optimize a preform shape out of a class of initial configurations and also to define the evolution of shapes and boundary tractions were developed. Discussions include the two problematic issues on internal tractions and the non-monotonous straining. For demonstration purposes, numerical calculations were made for a bulk part under forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.199-202
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• 2005

In this paper, the six sigma scheme is employed together with the rigid-viscoplastic finite element method to obtain the optimal metal flow lines in hot press forging. In general, the six sigma process is consisted of following five steps : define, measure, analyze, improve and control. Each step Is investigated in detail to meet customer's requirements through improvement of product quality. A forging simulator, AFDEX-2D, is used for analysis of the metal flow lines of a multi-stage hot forging process under various conditions of major factors, determined at each step of the six sigma process. The analyzed results are examined in order to reveal the effects of major factors on the metal flow lines and the formed shapes. The effects are used to find an optimal process and the optimal process with die is devised and tested. The comparison between required metal flow lines and experiments shows that the approach is effective for optimal process in hot forging design considering metal flow lines.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.539-542
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• 2008

Recently, GMP(Glass Molding Press) process is mainly used to produce aspheric glass lenses. Because glass lens is heated at high temperature above Ty (yielding point) for forming glass, the quality of aspheric glass lens is deteriorated by residual stresses which are generated in a aspheric glass lens after forming. Before this study, as a fundamental study to develop forming conditions for progressive GMP process, compression, strain relaxation and thermal conductivity tests were carried out to obtain the visco-rigid plastic, the visco-elastic and thermal properties of K-PBK40 which is newly developed and applied for precision molding glass material, In this study, using the experimental results we obtained, a glass lens forming simulation in progressive GMP process was carried out and we could forecast the shape of deformed glass lenses and residual stresses contribution in the structure of deformed glass lenses after forming.

• Geotechnical Engineering
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• v.11 no.3
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• pp.37-42
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• 1995

The laboratory hydraulic conducti vita tests with rigid wall permeameter were performed to study the effects of waste leachate on the permeability of a marine clay. The marine clay and waste leachate for this study were sampled from Kimpo Wastefills, and the hydraulic gradients applied to the clay specimens aTe relatively high from 37.5 to 225. The test results show that the permeability of a marine clay is increased with increasing the concentration of leachate and with decreasing the hydraulic gradient. And also both the liquid limit and the plasticity index of the marine clay miRed with waste leachate decrease with increasing the concentration of leachate.

• Transactions of Materials Processing
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• v.10 no.4
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• pp.338-346
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• 2001

Evaluation of microstructural changes is important for process control during open die forging of heavy ingots. The control of forging parameters, such as shape of the dies, reduction, temperature and sequence of passes, is to maximize the forging effects and to minimize inhomogeneities of mechanical properties. The hot working die steel is produced by using the multistage open die forging. The structure is altered during forging by subsequent Precesses of plastic deformation, recrystallization and grain growth. A numerical analysis using an rigid visco-plastic finite element model was performed to predict microstructural evolution of hot working die steel.

• Transactions of Materials Processing
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• v.7 no.3
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• pp.207-214
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• 1998

Influence of final thickness distribution in superplastic forming processes on mechanical properties of the product becomes very crucial. We should improve the thickness distribution of products by combining process parameters adequately In this paper we adopt a non-linear optimization technique for optimal process design of superplastic forming. And optimum design variable which makes the most adequate thickness distribution in combined stretc/blow forming and blow forming is predicted by this optimization scheme and rigid-viscoplastic finite element method.

• Transactions of Materials Processing
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• v.8 no.1
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• pp.101-107
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• 1999

The upset forging stage is the initial work in the forging process. It is used to remove the segregation and cavities of the ingot. Specially in handling large sized ingot, an improper upset forging can cause serious surface tearing. However, there is no detail reference for stable upset forging work. To resolve this difficulty, we studied several factors such as upset forging time, temperature varation of ingot, damage, load and stain rate etc., by using the rigid-plastic finite element approach available in the DEFORM code. Numerical simulation results indicated that: the load value of upset forging works shows severe decreasing trend at a certain point, same as strain rate. Also defects were found to be concentrated around the upper and lower portions of the ingot. With these results, we can estimate a guideline for stable upset forging work.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.340-346
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• 1999

Circular drawbead forming and drawing characteristics of CO2 laser welded SPC1 blanks are investigated by experiments and numerical analysis. During the drawbead forming process, the distributions of major strain on upper and lower skins of the specimens are measured. During the drawing process, the drawing forces and the strain distributions are investigated. For the numerical analysis. DYNA3D and SGTAS, a developed rigid-plastic finite-element computer program are used. Numerical results predicted the deformation characteristics well in comparison with experiments. It is concluded that the strains and restraining forces during the forming and the drawing processes show different patterns according to the combination of welded blanks.