• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.246-249
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• 1998

In the present study, domain decomposition using the substructuring method is developed for the computational efficiency of the finite element analysis of metal forming processes. In order to avoid calculation of an inverse matrix during the substructuring procedure, the modified Cholesky decomposition method is implemented. As obtaining the data independence by the substructuring method, the program is easily parallelized using the Parallel Virtual Machine(PVM) library on a workstation cluster connected on networks. A numerical example for a simple upsetting is calculated and the speed-up ratio with respect to various domain decompositions and number of processors. Comparing the results, it is concluded that the improvement of performance is obtained through the proposed method.

• Transactions of Materials Processing
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• v.8 no.3
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• pp.284-293
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• 1999

The rigid-plastic finite element analysis requires a large amount of computation time due to its non-linearity. For economic computation, mismatching refinement, and efficient domain decomposition method with different mesh density for each sub domain, is developed. A modified velocity alternating scheme for the interface treatment is proposed in order to obtain good convergence and accuracy. As a numerical example, the axisymmetric extrusion process is analyzed. The results are discussed for the various velocity update schemes form the viewpoint of convergence and accuracy. The three-dimen-sional extrusion process with rectangular section is analyzed in order to verify the effectiveness of the proposed method. Comparing the results with those of the conventional method of full region analysis, the accuracy and the computational efficiency of the proposed method are then discussed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.965-968
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• 1997

The objective of this study is to develop a rigid-thermoviscoplastic finite element program for the analysis of orthogonal cutting process. Deformation of the workpiece material is considered as rigid-viscoplastic and the numerical solution is obtained from the coupled analysis bctween plastic deformation and temperature field, including treament of temperature dependent material properties. The chip and the burr formation are simulated for the non-steady state orthogonal cutting using the developed program. To validate the program the predicted results at chip and burr format~on stage are compared with the published ones. The case of isothermal cutting process is also considered to study the thermal effect on the machining process.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.5
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• pp.45-52
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• 2001

In order to increase the productivity of electrical parts, manufacturing processes using progressive dies have been widely used in the industry. Motor cores have been fabricated using progressive stacking die with the lamination procedure for better electro-magnetic property. For the proper design off process, a prediction of the process is required to obtain many design parameters. In this work, rigid-plastic finite element analysis is carried out in order to simulate the lamination process of the motor core. The effects of the embossing depth, the amount of deviation, and the number of stacked sheets are investigated and compared with experiments. The forming process can then be predicted successfully from the results of analyses, which enables an appropriate design to be made for the die and the process.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.10
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• pp.1492-1499
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• 2004

In this paper, defect formation in ring rolling is revealed by computer simulation of ring rolling processes. The rigid-plastic finite element method is employed for this study. An analysis model having relatively fine mesh system near the roll gap is used for reducing the computational time and a scheme of minimizing the volume change is applied. The formation of the central cavity formation defect in ring rolling of a taper roller bearing outer race and the polygonal shape defect in ring rolling of a ball bearing outer race has been simulated. It has been seen that the results are qualitatively good with actual phenomena.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.5
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• pp.1562-1572
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• 1996

The rigid-plastic finite element formulation including the inertia force is derived and then the rigid-plastic finite elemnt program considering the inertia effect is developed. In order to consider the strain hardening, strain rate hardening and thermal softening effects which are frequentrly observed in high-velocity deformation phenomena, the Johnson-Cook constitutive odel is applied. The developed program is used to simulate two high-velocity deformation problemss ; rod impact test and hdigh-velocity compression precess. As a result of rod impact test simulation, it is found that the siulated result has a good agreement with the experimental observation. Through the high-velocity compression process simulation. it is also found that the accuracy of the simulated results is dependent upon the time increment size and mesh size.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.1
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• pp.153-161
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• 2002

This paper develops a finite element model for crashworthiness analysis ova small-sized bus. The full vehicle finite element model is composed of 31,982 shell elements,599 beam elements,42 bar elements, and 34,204 nodes. The model uses four material models (such as elastic, elastic-plastic(steel), rigid. and elastic-plastic (rubber) material model) of PAM-CRASH. The model uses four contact types to define sliding interfaces in ten areas. A frontal crash test using an actual vehicle with 30mph velocity to a rigid barrier is carried out. Vehicle pulses at lower part of left and right b-pillar are measured, and deformed shapes of frame and driver seat's lower left area are photographed. A frontal crash simulation using the developed full vehicle finite element model is performed with PAM-CRASH installed in super computer SP2. The simulation is performed with the same conditions as the test. The measured vehicle pulses and photographed deformed shapes from the test are compared to ones from the simulation to validate the reliability of the developed model.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.192-198
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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.

• Journal of Environmental Science International
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• v.16 no.10
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• pp.1169-1177
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• 2007

The main objective of this research was to evaluate the effects of process variables which were forming ability, flow displacement, effective stress, effective strain, fluid vector and products defects on manufactured artificial lightweight aggregate made of both incinerated sewage sludge ash and clay by means of the numerical analysis of a rigid-plastic finite element method. CATIA (3D CAD program) was used for an extrusion metal mold design that was widely used in designing aircraft, automobile and metallic molds. A metal forming analysis program (ATES Co.) had a function of a rigid-plastic finite element method was used to analyze the program. The result of extrusion forming analysis indicated clearly that a shape retention of the manufactured artificial light-weight aggregate could be maintained by increasing the extrusion ratio (increasing compressive strength inside of extrusion die) and decreasing the die angle. The stress concentration of metal mold was increased by increasing an extrusion ratio, and it was higher in a junction of punch and materials, friction parts between a bottom of the punch and inside of a container, a place of die angle and a place of die of metal mold. Therefore, a heat treatment as well as a rounding treatment for stress distribution in the higher stress concentration regions were necessary to extend a lifetime of the metallic mold. A deformity of the products could have made from several factors which were a surface crack, a lack of the shape retention and a crack of inside of the products. Specially, the surface crack in the products was the most notably affected by the extrusion ratio.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.6
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• pp.725-731
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• 1985

In this study the rigid-plastic finite element method is used in order to study the deformation characteristics of solid cylinder upsetting. The effects of friction and aspect ratios on the effective strain distribution, axial stresses at the die-material interface, radial displacements, strain components, grid distortion on the meridional cross-section and gradual changes of outer profile are studied analyzed and compared with the experiments for commercially pure aluminum and .alpha.-brass. The agreement between numerical (or theoretical)and experimental results is shown to be acceptable for the engineering purpose.