• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.06a
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• pp.1-9
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• 1994

Three recent developments made at Rensselaer in sheet material forming processes are briefly reviewed in this paper. These advances represent three broad disciplines of Process Simulation, Forming Processes, and Computer-Aided Measurement Methods. The first development deals with simple and quick computer simulation of 2D sheet forming process without depending on popular finite element analysis methods. An analytical method based on a thin shell theory accounts for bending and unbending effects, and is capable of simulating practical sheet metal forming processes under the plane strain condition. The second area is concerned with innovative methods to improve formability of sheet materials by temperature gradient forming. The drawing limit is increased by such an improved temperature gradient forming process. The third and final area deals with a totally new experimental technique to capture 3D geometry data and measure strain distributions of sheet metal parts using a digital 35mm SLR camera.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.10a
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• pp.44-54
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• 1994

A variational formulation and the associated finite elemet equations have been derived for general three-dimensional deformation of a planar anisotropic rigid-plastic sheet metal which obeys the strain-rate potential proposed by BARLAT et al [13]. By using the natural convected coordinate system, the effect of geometric change and the rotation of planar anisotropic axes are considered efficiently. In order to check the validity of present formulation, a cylindrical cup and a square cup deep drawing test was modeled. good agreement was found between the FE simulation and the experiment. The results have shown that the present formulation for planar anisotropic deformation can be efficiently applied to the analysis of sheet metal working processes for planar anisotropic nonferrous metals.

• Transactions of Materials Processing
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• v.9 no.1
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• pp.17-26
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• 2000

A series of parametric study was performed for the investigation on the influence of analysis parameters to the solution behavior in the elastic-plastic-static analysis of several sheet metal forming processes, such as deflection by a point force under plane strain and axisymmetric conditions, plane strain bending by a punch, axisymmetric stretching by a punch, axisymmetric bulging by hydraulic pressure, and axisymmetric deep drawing by a punch. The parameters considered are kind of element, number of elements, integration scheme for elemental equation and friction coefficient. Results obtained for different selections of those parameters were compared with each other, experimental measurements and analytical solution.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.696-703
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• 2004

The purpose of this study is to examine the bulk/sheet forming characteristics of bulk amorphous alloys in the super cooled liquid state. Recently it is reported that amorphous alloys exhibit stress overshoot/undershoot and non-Newtonian behaviors even in the super cooled liquid state. The stress-strain curves with the temperature-dependences as well as strain-rate dependence of Newtonian/non-Newtonian viscosities of amorphous alloys are obtained based on the previous experimental works. Then, those curves are directly used in the thermo-mechanical finite element analyses. Upsetting and deep drawing of amorphous alloys are simulated to examine the effects of process parameters such as friction coefficient, forming speed and temperature. It could be concluded that the superior formability of an amorphous alloy can be obtained by taking the proper forming conditions.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.171-182
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• 1998

An automated surface-strain measuring system using the image processing technique is developed in the present study, which consists of the hardware to capture and to display digital images, and the software to calculate the 3D informations of grid points from two views. New or improved algorithms the mapping and establishing correspondence of grid points and elements, the camera calibration, and the subpixel measurement of grid points, are implemented. As an application of the present system the surface-strains of deformed blanks in the limitting dome height test, the square cup deep-drawing and punch stretching to obtain the forming limit diagram are measured. The results are compared with those obtained by conventional manual methods.

• Journal of the Korean Society for Precision Engineering
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• v.11 no.2
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• pp.104-109
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• 1994

This research describes some developments of computer-aided process planning and die design for hot forging products of H-shaped plane strain produced by the press. The system is composed of three main modules(process planning module, die design module and simulation module) which are used independently or in all. Systm capabilities include as follows: 1. In die design module, using the results of process planning module, the shape and size of bolcker and finish die in each operation are determined and the ouput id generated in graphic form for manufacturing drawing. 3. In simulation module, the flow pattern of workpiece and the load/stroke curve are approximately predicted. Design rules for process planning and die design are extracted from plasticity theories, handbooks, relevant references and empirical know-how of field experts in hot forging companies. The developed system provides poweful capabilities for process planning and die design of hot forging products.

• Advances in materials Research
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• v.2 no.2
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• pp.111-118
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• 2013

The changes of plastic plateau in the stress-strain curves of annealed polypropylene (PP) films during stretching under room temperature were followed and the corresponding melting properties and microstructure were characterized by differential scanning calorimetry (DSC) and scanning electron microscopy (SEM). It was found that during stretching the plastic plateau disappeared progressively with the increase of drawing ratio. At the same time, the endotherm plateau in DSC curves also disappeared progressively. The presence of the plastic plateau was attributed to the stretching of unstable crystalline part which was formed by tie chains around initial row-nucleated lamellae structure during annealing. During stretching, the unstable part was stretched and converted to bridges connecting separated lamellae. There was direct relationship between the disappearance of plastic plateau and pore formation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.08a
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• pp.163-171
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• 1999

The abnormal grain coarsening in wire rolling induces detrimental defects, such as jagged size tolorance, severe bending after heat treatments and drawing troubles, in the following secondary processes. Neishi et al observed that there is a band type region where grain coarsenting occurs in the plastic strain vs. deformation temperature plot. Based on the finding, we have investigate whether grain sizes and ferrite volume fractions are correlation to deformation strain with three kinds of wire rod diameters as for the different average deformation conditions. The samples were chosen from the No.2 Wire Rod Mill of POSCO where 3-roll type of finishing mill stand are used. It was found in the present work that the grain size and ferrite volume fraction of the rolled and cooled microstructure were changed with rolling reduction and rolling temperature. Abnormally grown grains at various observed points were also found. To have homogeneously fine grains of microstructure from the No. 2 Wire Rod Mill, it will be easier to control finish rolling temperature at around 750$^{\circ}C$ rather than to find another rolling schedule.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.66-70
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• 2008

In this study, the formability of AZ31B magnesium alloy sheets was investigated by the analytical and experimental approaches. Tensile tests and limit dome height tests were rallied out at several temperatures between $25^{\circ}C$ and $300^{\circ}C$ to obtain the mechanical properties and forming limit diagram (FLD). The FLD-based criterion considering the strain-path and the blank temperature was used to predict the forming limit in a deep-drawing process of cross-shaped cup by finite element analysis. This criterion proved to be very useful in determining the optimal process conditions such as blank shape, punch velocity, minimum comer radius, fillet size, and so on, through the comparison between FEA and experimental data. In particular, the temperature of each tool that provided the best formability of the blank was determined by coupled temperature-deformation analyses. A practical method that can greatly reduce the forming time by increasing the punch speed during the forming process was suggested.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.269-273
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• 2003

There is a growing interest to replace the commercial steels with non-heat treated steels, which does not involve the spheroidization and quenching-tempering treatment. However, Non-heat treated steels should satisfy high strength and good formability without performing heat treatment. Therefore, it is important to investigate optimum materials showing a good combination of strength and formability after the drawing process. In this study, Dual-Phase Steels were studied as candidate materials for non-heat treated steels, which have different martensite morphologies and volume fractions obtained through heat-treatment of intercritical quenching (IcQ), intermediate quenching (ImQ) and step quenching (SQ). The mechanical properties of DP steels were measured by tension and compression tests. Also, the cold formability of three DP steels which have similar tensile strength value was investigated by estimating the deformation resistance and the forming limit. The deformation resistance which is important factor in determining die life was estimated by calculating the deformation energy. And the forming limit was estimated by measuring the critical strain revealing crack initiation at the notch tip of the specimens.