• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.3
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• pp.78-85
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• 2008

Roll forming process is one of the most widely used processes in the world for forming metals. It can manufacture goods of the uniform cross section throughout the continuous processing. However, process analysis is very difficult because of the inherent complexity. Therefore, time is consuming and much money are needed for manufacturing goods. In order to overcome this difficulty, a new computational method based on the rigid-plastic finite element method is developed for the analysis of roll forming process. In this paper, the design of roll forming process and the simulation are performed to manufacture the upper member at under rail composed of three members. The cold rolled carbon steel sheet(SCP-1) is used in this simulation, and a flow stress equation is set up by conducting the tensile test. The upper member is designed using two types of design for a excellent design. Each types are simulated and compared with the strain distribution using SHAPE-RF software. In addition, the numerical magnitude of bow and camber which are the buckling phenomenon is estimated.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.6
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• pp.395-399
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• 2017

The LPI fuel filter housings used in automobiles were made from conventional die castings but have recently been developed by cold forging to improve the weight and durability. On the other hand, a sink may develop at the core of the forged product due to the resulting T-shape, which not only reduces the aesthetics, but also increases the post-processing cost of the product. Therefore, this research focused on methods to predict and mitigate sink development and progression during the T-shape forging process. Finite element analysis of the forging process was first performed to determine the optimal initial workpiece devoid of burrs and underfills. An accurate sink prediction was then obtained via metal flow analysis, which was a result of the finite element simulation. Through finite element analysis, it was confirmed that sink development is a product of the differences in nodal velocities arising from the T-shaped forging process. Consequently, a pad was inserted beneath the sink to minimize these velocity differences. The results yielded significant improvement with regard to the sink defect. This method was practically applied to an industrial site to validate the sink improvement.

• Transactions of Materials Processing
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• v.17 no.2
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• pp.124-129
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• 2008

Net shape forging technologies give many effects into the costs and qualities for the finished products. So, the studies to reduce the additional machining amount are very important in forging industry. Specially, there are two main topics in cold forging industry, such as, tool life and precision forging. In this study, new forging technique was proposed to eliminate the machining process for fixing up the length and improve the lead accuracy of gear. The luck-up hub is manufactured through many processes, such as upsetting, piercing and direct extrusion. The gear is formed in direct extrusion process; however, lead accuracy of the gear is over allowance limit. Therefore, the additional sizing process must be added. 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.

• Design & Manufacturing
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• v.8 no.2
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• pp.30-36
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• 2014

In this study, surface deformation patterns have been investigated by the rigid-plastic finite element method for friction factor test in solid cylinder compression process. AA1100 and AA6063 aluminum alloys, which show different work hardening characteristics respectively, have been adopted as model materials used for analysis. The main objective of this study is to provide the deformation mechanics in detail in solid cylinder compression process, especially at the die/workpiece interface that is closely related with the frictional conditions. For this reason, solid cylinder compression process has been numerically analyzed. The surface flow patterns at the contact boundary have been analyzed in terms of surface expansion, surface expansion velocity, pressure distributions exerted on the die surface along the die surface. By defining bulge factor, barreling phenomenon also have been examined with calibration curves to verify their effects on the surface flow pattern that is important for evaluating the frictional condition at the interface.

• Structural Engineering and Mechanics
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• v.41 no.6
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• pp.805-822
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• 2012

Offshore pipelines have to withstand combined actions of tension and bending during deepwater installation, which can possibly lead to elliptical buckle and even catastrophic failure of whole pipeline. A 2D theoretical model initially proposed by Kyriakides and his co-workers which carried out buckling response analysis of elastic-plastic tubes under various load combinations, is further applied to investigate buckling behavior of offshore pipelines under combined tension and bending. In association with practical pipe-laying circumstances, two different types of loadings, i.e., bent over a rigid surface in the presence of tension, and bent freely in the presence of tension, are taken into account in present study. In order to verify the accuracy of the theoretical model, numerical simulations are implemented using a 3D finite element model within the framework of ABAQUS. Excellent agreement between the results validates the effectiveness of this theoretical method. Then, this theoretical model is used to study the effects of some important factors such as load type, loading path, geometric parameters and material properties etc. on buckling behavior of the pipes. Based upon parametric studies, a few significant conclusions are drawn, which offer a theoretical reference for design and installation monitoring of deepwater pipelines.

• Journal of Power System Engineering
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• v.16 no.6
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• pp.52-58
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• 2012

Roll forming process is one of the most widely used processes in the world for forming metals such as a furniture drawer guide or an up and down slide guide. It can manufacture goods of the uniform cross section on a large scale throughout the continuous processing. In the domestic design and manufacture, roll forming process for production is taking most of the method of 2-point under rail slide. However, this method is vulnerable to the structural strength and stiffness is not suitable for high load conditions. Therefore, through systematic study of high load, low noise 3-point ball type of under rail slide its own design and manufacturing technology is the need to build. In this paper, to make center member of 3-point ball-type under rail slide for the refrigerator doors, the roll forming modeling and simulation are performed. Tensile test is performed about SCP-1 1/2H for determine the mechanical properties of materials. Modeling and simulation of roll forming is used MSC.MARC software of a dedicated analysis program used by rigid plastic finite element method. Interference between the roll and the final shape are predicted from the results of the simulation.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.603-613
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• 2007

This paper is concerned with joining of thin metal sheets by single stroke clinching process. This method has been used in sheet metal work as it is a simple process and offers the possibility of joining similar-dissimilar thin sheet metals. Clinching generates a joint by overlapping metal sheets deforming plastically by punching and squeezing sequence. AA 5754 aluminum alloy of 0.5 mm thick sheets have been selected as a modal material and the process has been simulated under different process conditions and the results have been analyzed in terms of the quality of clinch joints which are influenced mainly by tool geometries. The rigid-plastic finite element method is applied to analyses in this paper. Analysis is focused mainly on investigation of deformation and material flow patterns influenced by major geometrical parameters such as die diameter, die depth, groove width, and groove corner radius, respectively. To evaluate the quality of clinch joints, four controlling or evaluation parameters have been chosen and they are bottom, neck thickness of bottom and top sheets, and undercut thickness, respectively. It has been concluded from the simulation results that the die geometries such as die depth and diameters are the most decisive process parameters influencing on the quality of clinch joints, and the bottom thickness is the most important evaluation parameter to determine if the quality of clinch joints satisfies the demand for industrial application.

• Journal of the Korean Geotechnical Society
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• v.19 no.3
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• pp.53-64
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• 2003

Many transmission towers, high-rise buildings and bridges are constructed near steep slopes and are supported by large-diameter piles. These structures may be subjected to large lateral loads, such as violent winds and earthquakes. Widely used types of foundations for these structures are pier foundations, which have large-diameters with high stiffness. The behavior of a pier foundation subjected to lateral loads is similar to that of a short rigid pile because both elements seem to fail by rotation developing passive resistance on opposite faces above and below the rotation point, unlike the behavior of a long flexible pile. This paper describes the results of several numerical studies performed with a three-dimensional finite element method (FEM) of model tests of a laterally loaded short pile located near slopes, respectively. In this paper, the results of model tests of single piles and pile groups subjected to lateral loading, in homogeneous sand with 30$^{\circ}$ slopes and horizontal ground were analyzed by the 3-D FE analyses. The pile was assumed to be linearly elastic. The sand was assumed to have non-associative characteristics, following the MC-DP model. The failure criterion is governed by the Mohr-Coulomb equation and the plastic potential is given by the Drucker-Prager equation. The main purpose of this paper is the validation of the 3-D elasto-plastic FEM by comparisons with the experimental data.

• Transactions of Materials Processing
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• v.16 no.7
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• pp.521-529
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• 2007

This paper is concerned with the analysis on the surface expansion of AA 2024 and AA 1100 aluminum alloys in backward extrusion process. Due to heavy surface expansion appeared usually in the backward can extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the surface expansion is analyzed especially under various process conditions. The main goal of this study is to investigate the influence of degree of reduction in height, geometries of punch nose, friction and hardening characteristics of different aluminum alloys on the material flow and thus on the surface expansion on the working material. Two different materials are selected for investigation as model materials and they are AA 2024 and AA 1100 aluminum alloys. The geometrical parameters employed in analysis include punch corner radius and punch nose angle. The geometry of punch follows basically the recommendation of ICFG and some variations of punch geometry are adopted to obtain quantitative information on the effect of geometrical parameters on material flow. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward can extrusion process under different geometrical, material, and interface conditions. The simulation results are summarized in terms of surface expansion at different reduction in height, deformation patterns including pressure distributions along the interface between workpiece and punch, comparison of surface expansion between two model materials, geometrical and interfacial parametric effects on surface expansion, and load-stroke relationships.

• Journal of the Korean Geosynthetics Society
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• v.21 no.2
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• pp.57-65
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• 2022

This study simulated the shock wave propagation through the tamping material between explosives and hole wall at blasting works and verified the effect of tamping materials. The Arbitrary Lagrangian-Eulerian(ALE) method was selected to model the mixture of solid (Lagrangian) and fluid (Eulerian). The time series analysis was carried out during blasting process time. Explosives and tamping materials (air or water) were modeled with finite element mesh and the hole wall was assumed as a rigid body that can determine the propagation velocity and shock force hitting the hole wall from starting point (explosives). The numerical simulation results show that the propagation velocity and shock force in case of water were larger than those in case of air. In addition, the real site at blasting work was modeled and simulated. The rock was treated as elasto-plastic material. The results demonstrate that the instantaneous shock force was larger and the demolished block size was smaller in water than in air. On the contrary, the impact in the back side of explosives hole was smaller in water, because considerable amount of shock energy was used to demolish the rock, but the propagation of compression through solid becomes smaller due to the damping effect by rock demolition. Therefore, It can be proven that the water as the tamping media was more profitable than air.