• 한국정밀공학회지
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• 제22권3호
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• pp.86-92
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• 2005

In this paper a forward-backward can extrusion process are analyzed by using rigid-plastic FEM simulation. FEM simulation is conducted to investigate forming characteristics such as deformation modes fur different process parameters. Design parameters such as thickness ratio, punch angle, friction factor and diameter ratio are selected to study the effect of them on the pattern of material flow. The analysis is focused mainly on the influences of the design factors on deformation pattern in terms of forming load, extruded length ratio and volume ratio. It is known for the simulation that the forming load, the length ratio and the volume ratio increase as the thickness ratio (TR), the wall thickness in forward direction to that in backward direction, decreases. The various punch angles have slight influence on the forming load. length ratio and volume ratio. However friction factor have little effect on the forming characteristics such as the forming load, volume ratio and so on. In addition the forming load increases as diameter ratio (DR), the outer diameter of a can in forward direction to that in backward direction, increases. Furthermore the extruded length ratio is lowest with a certain value of DR=0.85 among diameter ratios. Pressure distribution exerted on the die-material interface is illustrated schematically.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 추계학술대회 논문집
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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.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 추계학술대회 논문집
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• pp.220-223
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• 2001

Until now, the clamp yoke of automobile has been largely manufactured by hot forging or burring process. Through the study, the precision cold forging process for clamp yoke has been analysed by using rigid-plastic finite element analysis code, DEFORM-3D. It has shown various results of the FEM simulation. An engineer should select the proper process considering the amount of product.

• 소성∙가공
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• 제4권1호
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• pp.79-91
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• 1995

Precision forming of electronic components has appeared to be competitive according to manufacturing cost and dimensional tolerances. Now domestic electronic companies have been involving in utilization of the finite element method in process design of precision forming. A forming process to produce an electronic component, aperture, has been inbestigated to find out forming defects during multi-operations. The applications of the commercial FEM software MARC show a possibility of defect in precision coining process among the whole multi-process. Thus the coining process of three-dimensional deformation is analyzed using DAMF-3D which has been developed in this lab with the rigid-plastic algorithm. The result f simulations by DAMF-3D provides clear description of the defect involved in the coining process.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.1686-1690
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• 2005

Although metal ball can be used as parts of bearing or metal filter, that is used by single product with solder ball or shot ball. Also, according as demand of metal ball of various diameter increase, processing property 솜 extension of coverage are important. Especially an optimal design of cutting roller was investigated for determining appropriate dimensions of components of manufacturing system. In this study, the effects of the diameter and the round radius of cutting roller were calculated and analyzed. We applied data of rigid-plastic FEM Simulation in basis design of equipment to solve these issues, and confirmed processing factor about metal ball manufacturing process that use cutting process of metal wire in this research

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 춘계학술대회논문집
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• pp.439-442
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• 2003

This study presents a new computational model to analyze the grain deformation in a polycrystalline aggregate in a discrete manner and based directly in the underlying physical micro-mechanisms. As a result, specific characteristics have to be considered for the numerical analysis. The grains and grain boundary elements are introduced to model individual grains and grain boundary facets, respectively, to consider the size effects in the micro forming. The constitutive description of the grain elements accounts for the rigid-plastic and the grain boundary elements for elastic relationships. The capability of the proposed approach is demonstrated through application of grain element and grain boundary element in the micro forming.

• 한국정밀공학회지
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• 제17권6호
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• pp.143-152
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• 2000

The comer filling in shaped drawing process is an important characteristic, unlike the round drawing. It has also influence on the dimensional accuracy of the product. In this study, therefore, the shaped drawing process has been simulated by the three dimensional rigid-plastic finite element method in order to investigate the effect of process variables such as reduction in area and semi-die angle to the corner filling. The artificial neural network has also been introduced to reduce the number of simulations. To verify the results of simulations, experiments have been performed on the real industrial products. According to the results, the main process variable on the corner filling is the combination of semi-die angle in the irregular shaped drawing processes, but in the case of regular shaped drawing processes, reduction in area has great influence on the corner filling.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1999년도 압출 및 인발 심포지엄
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• pp.56-59
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• 1999

In the present study, in order to investigate the effect of the corner filling in the drawing of the rectangular rod from a round bar, the drawing of the square rod from a round bar has been simulated by using rigid-plastic finite element method and artificial neural network has been introduced to reduce the number of simulation. The experimental investigation has been also implemented to verify the efficiency of the application of results of present and previous study. According to the results of present and pervious study, the combination of semi-die angle gives a great effect on the corner filling in case of the irregular shaped drawing process, but, in case of the regular shaped drawing process, the main process variable on the corner filling is reduction in area.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 추계학술대회 논문집
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• pp.62-65
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• 2000

For saving time and cost of experiment Finite Element Method has been developed for several decades. It's the defect of FEM that when we are in processing of finite element analysis, the material if deformed so much that we can't proceed analysis any more. In this case, the remeshing process should be done on this material. In hot forging process, almost all remeshing process does not consider flash of the material. Because as mesh size become swatter, consuming time become larger. But if mesh size is big, there is the defect that the result of analysis is not so accurate. So, new remeshing algorithm is needed to save time and to get more accurate result.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1999년도 춘계학술대회논문집
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• pp.99-102
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• 1999

In this study, to investigate the effect of process variables such as reduction in area, semi-die angle and the rectangular ratio to the corner filling which influences the dimensional accuracy of the final product in the drawing of the cluadrangle rod from a round bar, it has been simulated by three dimensional rigid-plastic finite element method. In order to reduce the number of simulation artificial neural network has been introduced. Also, through the experimental investigation, the present results have been implemented on the industrial product. In results, the main process variable is the combination of the semi-die angle in case of the irregular shaped drawing process and reduction in area in the event of regular shaped drawing process, respectively.