• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.03a
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• pp.224-232
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• 1995

A process is designed by the backward tracing scheme of the rigid-plastic FEm for net-shape shell nosing component without machining after forming. The current process of the shell nosing industry requires cost-consuming machining to produce final product . The backward tracing scheme of the rigid-plastic FEM, a novel method in preform design of metal forming processes , derives a sound preform for net-shape shell nosing product . The current process is simulated to check the metal flow involved informing with a trial preform and its modified preform. It is found that the two preforms are not suitable for net-shape shell nosing product. Finally, a preform is desinged by the backward tracing scheme, which is suitable for net-shape manufacturing of the shell nosing component.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.45-48
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• 1999

A program for initial blank design in sheet forming which contains the capabilities of forward loading simulation by the finite element method and backward tracking simulation has been developed and proved the effectiveness by applying to a square cup stamping process. In the blank design of square cup stamping the backward tracing program can produce an optimum blank configuration which forms a sound net-shape cup produce without machining after forming. Another general application appears in the blank design of a cup stamping with protruding flanges one of typical automobile components. The blank configurations derived by backward tracing simulation have been confirmed by a series of loading simulations. The approach for decision of an initial blank configuration presented in this study will be a milestone in fields of sheet forming process design.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.49-52
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• 1999

Tailored-welded blanks are used for forming of automobile structural and skin components. Its main objective is to achieve weight and production cost reduction in manufacturing of the components. For successful application of tailored-welded blanks design of initial welded blanks and prediction of welding line movement are critical. Here the utilization of the backward tracing scheme of the finite element method shows to be desirable in design of initial welded blanks for net-shape production and in prediction of the welding line movement. First the design of initial blank in forming of welded thick sheet with isotropy is tried and it appears successful in obtaining a net-shape stamping product. Based in the first approach the backward tracing scheme is applied to anisotropic tailored blank. The welding line movement is also discussed.

• Transactions of Materials Processing
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• v.26 no.5
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• pp.300-305
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• 2017

In this paper, a design method for an intermediate die was developed to manufacture a hollow linear motion guide rail in mandrel drawing process based on virtual die method and backward tracing scheme. FE simulations and mandrel drawing experiments using Mn55Cr carbon steel were performed to prove the effectiveness of the proposed design method. Results of FE simulations and experiments showed that the proposed design method could lead to drawn products with sound shape and the highest dimensional precision.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.351-354
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• 2003

Titanium alloys are a vital element for developing advanced structural components, especially in aerospace applications. However, process design for successful forming of titanium alloy is a difficult task, which is to be achieved within a very narrow range of process parameters. Presented in this paper is a finite element - based optimal design technique as applied to ductile fracture minimization process design in backward extrusion of titanium alloys.

• Transactions of Materials Processing
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• v.14 no.9 s.81
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• pp.772-778
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• 2005

This paper is concerned with the analysis of material flow characteristics of combined tube extrusion using pipe. The analysis in this paper concentrated on the evaluation of the design parameters for deformation patterns of tube forming, load characteristics, extruded length, and die pressure. The design factors such as punch nose radius, die corner radius, friction factor, and punch face angle are involved in the simulation. The combined tube extrusion is analyzed by using a commercial finite element code. This simulation makes use of pipe material and punch geometry on the basis of punch geometry recommended by International Cold Forging Group. Deformation patterns and its characteristics in combined forward and backward tube extrusion process were analyzed for forming loads with primary parameters, which are various punch nose radius relative to backward tube thickness. The results from the simulation show the flow modes of pipe workpiece and the die pressure at the contact surface between pipe workpiece and punch. The specific backward tube thickness and punch nose radius have an effect on extruded length in combined extrusion. The combined one step forward and backward extrusion is compared with the two step extrusion fer forming load and die pressure.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.575-578
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• 2000

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation for the die wear is too hard because the prediction of the die wear is determined with many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard's wear model in order to reduce the rapid wear rate that is generated for the backward extrusion product exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat, angle, and round of the punch nose part. As the flat and angle of the punch nose are larger, the surface expansion is reduced. and, the wear rate is decreased according to the reduction of the punch round. These results obtained through this study are applied to the real manufacturing process, it is implemented the reduction of the wear rate.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.10
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• pp.180-187
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• 2004

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation fur the die wear is too hard because the die wear is caused by many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard wear model in order to reduce the rapid wear rate that is generated for the backward extruded products exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat diameter, angle, and round of the punch nose part. As the flat diameter and angle of the punch nose are larger, the surface expansion is reduced and the wear rate is decreased according to the reduction of the punch round. These results obtained through this study can be applied to the real manufacturing process.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.5
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• pp.576-582
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• 2015

Generally, the fuel economy of hybrid electric vehicle (HEV) is effected by the size of each component. In this study the fuel economy for HEV of our own making is evaluated using backward simulator, where dynamic programming is applied. In a competition, the vehicle is running through the road course that includes many speed bumps and steep grade. Therefore, the new driving cycle including road grade is developed for the simulation. The backward simulator is also developed through modeling each component. A performance map of engine and motor for component sizing is made from the existing engine map and motor map adapted to the HEV of our own making. For optimal component sizing, the feasible region is defined by restricting the power range of power sources. Optimal component size for best fuel economy is obtained within the feasible region through the backward simulation.

• 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.