• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.128-131
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• 2009

In this paper, three-dimensional finite element analysis of screw rolling process of a long shaft bolt is conducted by using a rigid-plastic finite element method based metal forming simulator AFDEX 3D. A whole sequence of cold forming processes of a long shaft bolt composed of forging and screw rolling processes is simulated to reveal the mechanism of screw formation. A mesh density control function is applied near the major plastic deformation region to achieve computational efficiency.

• Transactions of Materials Processing
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• v.19 no.4
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• pp.248-252
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• 2010

In this paper, three-dimensional finite element analysis of thread rolling process of a 12 point flange head bolt is conducted using a rigid-plastic finite element method based metal forming simulator AFDEX 3D. A whole sequence of cold forming processes of a long shaft bolt composed of four forging stages and final thread rolling process is simulated to reveal the mechanism of thread formation. A mesh density control function is applied near the major plastic deformation region to achieve computational efficiency. It has been shown both numerically and experimentally that longitudinal lengthening or shortening is negligible in thread rolling.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.258-261
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• 2003

In this study, finite element analysis for multi-stage deep drawing process of rectangular configuration with extreme aspect ratio is carried out especially for the blank design. The analysis of rectangular deep drawing process with extreme aspect ratio is likewise very difficult with respect to the design process parameters including the intermediate die profile. In order to solve the difficulties, numerical approach using finite element method is performed in the present analysis and design. A series of experiments for multi-stage rectangular deep drawing process are conducted and the deformed configuration is investigated by comparing with the results of the finite element analysis. Additionally, to minimize amount of removal material after trimming process, finite element simulation is applied for the blank modification. The analysis incorporates brick elements for a rigid-plastic finite element method with an explicit time integration scheme using LS-DYNA3D.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 2001.11a
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• pp.331-340
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• 2001

Elastic-Plasitc Finite element analysis is peformed about the TiN coated medium. The normal contact is simulated by a rigid asperity pressing the surface of an elastic-plastic half-surface. The case of a surface film stiffer than the substrate is considered, and general solutions for the subsurface stress and deformation fields are presented for several coating thickness. Additionally, the critical normal loads for deformation in the substrate and coating fracture are calculated when the yield of TiN film follows the Maximum Principal Stress Theory and Von Mises Theory. The results can be subsumed in failure maps for TiN thin film on steel.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03b
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• pp.130-137
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• 1996

Several cold extrusion processes to produce an axisymmetric steel piston-pin are investigated for comparing each other. Two methods among four conventinal ones are selected to be simulated using the rigid-plastic finite element method. One of the both methods using a mechanical press has one stage process and the other utilizing a cold header applies a multi-stage process to produce a final product. Because the main process is a backward extrusion, the design criteria such as the backward extrusion ration and punch diameter to depth rationare ocnsidered. FEM analysis is performed mainly for strain distributin and load-stroke relationshis. Based on the results of preliminary simulatin, both process sequences are proved to have proper charicteristics suitable for each production method in terms of maximum load. Those simulation results will be a good design criteria in the future work to advance the manufacturing process.

• Journal of Korean Society of Steel Construction
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• v.23 no.5
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• pp.535-546
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• 2011

In this paper, semi-rigid elasto-plastic post-buckling analysis of a space frame was performed using various explicit arc-length methods. Various explicit arc-length methodsand a large-deformation and small-strain elasto-plastic 3D space frame element with semi-rigid connections and plastic hinges were developed. This element can be appliedto both explicit and implicit numerical algorithms. In this study, the Dynamic Relaxation method was adopted in the predictor and corrector processesto formulate an explicit arc-length algorithm. The developed "explicit-predictor" or "explicit-corrector" were used in the elasto-plastic post-buckling analysis. The Eulerian equations for a beam-column with finite rotation, which considers the bowing effects, were adopted for the elastic system and extended to theinelastic system with a plastic hinge concept. The derived tangent stiffness matrix was asymmetrical due to the finite rotation. The joint connection elements were introduced for semi-rigidity using a static condensation technique. Semi-rigid elasto-plastic post-buckling analyses were carried out to demonstrate the potential of the developed explicit arc-length method and advanced space frame element in terms of accuracy and efficiency.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.6
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• pp.1411-1421
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• 1995

A rigid visco-plastic finite element method has been developed for modeling superplastic forming processes. The optimum pressure-time relationship for a target strain rate and thickness distributions was predicted using two-node line element based on membrane approximation for plane strain and axisymmetric condition. Analysis of superplastic forming was carried out using the developed program and the numerical results were compared to the values available in the literature for plane strain problems. For description of the contact between the dies and sheet, the direct projection method was applied to the complicated problem and the validity of the scheme was tested. Experiments for the various geometries such as hemisphere and cone were performed with the developed forming machine using the calculated optimum pressure-time curves. Comparison between analysis and experiments showed good agreement.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.6
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• pp.876-888
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• 1986

The Study is concerned with the analysis of unconstrained axisymmetric piercing as a nonsteady forging process by the rigid-plastic finite element method. In the numerical analysis of axisymmetric piercing, the initial velocity field is generated by assuming the material as a linear viscous material to begin with in order to facilitate the input handling and to ensure better convergencey. The strain-hardening effect for nonsteady deformation and the friction of the die-material interial interface are considered in the formulation. Rigid body treatment is also incorporated in the developed program. The experiments are carried out for aluminum alloy specimens (A1204) with different specimen heights. It is shown that the experimental results are in excellent agreement with the finite element simulations is deformed configuration. For load prediction the theoretical prediction shows excellent agreement with th eexperimental laod in the initial stage of loading before fracture of the specimen is not initiated. Distribution of stresses, strains and strain rates has been found for the given cases in computation. On this basis several fracture criteria are introduced in order to check the fracture initiation. It is found that maximum shear criterion is capable of good fracture prediciton.

• Journal of Advanced Marine Engineering and Technology
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• v.28 no.1
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• pp.83-89
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• 2004

Flare nut is an important Part that used to joint a brake tube-end in automobiles. It was made of SWCH 10A by machining. But we studied to make it by metal forming. The main focus of this paper is to investigate an optimal forging processes for flare nut using the DEFORM$^{TM}$-3D. commercially available finite element code and tests. Actually an explicit finite element analysis of the flare nut forging processes has been carried out to predict an optimal shape of the flare nut and its results were reflected in the tests of the forging processes design for flare nut. The simulation results which had obtained from finite element analysis were contributed to the forging processes design for flare nut. An optimal shape of nave nut showed agreements with test results. Furthermore. this paper should contribute to a development of the forging process for a variety of parts.s.