• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.2
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• pp.61-66
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• 2010

A virtual manufacturing system that is composed of JMatPro, a material modeler and $DEFORM^{TM}$-HT, a finite element package is applied to the hot press forming process: high temperature material properties for each phase such as flow stress, elastic modulus, Poisson's ratio, thermal expansion coefficient, in addition to TTT curve are predicted by JMatPro and taken into $DEFORM^{TM}$-HT to predict the material behavior considering phase transformation and heat transfer simultaneously. In order to verify the accuracy of computation, the residual stress and the springback were compared with the experimental measurements. Both the predicted and measured principal residual stresses and amount of springback were in good agreement. It was also found that the residual stresses generated from hot press forming are not negligible as it has been generally assumed, although the springback deformation is quite small.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.43-46
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• 2005

Micro molding technology is a promising mass production technology for polymer based microstructures. Mass production technologies such as the micro injection/compression molding, hot embossing, and micro reaction molding are already in use. In the present study, we have developed a numerical analysis system to simulate three-dimensional non-isothermal cavity filling for hot embossing, with a special emphasis on the free surface capturing. Precise free surface capturing has been successfully accomplished with the level set method, which is solved by means of the Runge-Kutta discontinuous Galerkin (RKDG) method. The RKDG method turns out to be excellent from the viewpoint of both numerical stability and accuracy of volume conservation. The Stokes equations are solved by the stabilized finite element method using the equal order tri-linear interpolation function. To prevent possible numerical oscillation in temperature Held we employ the streamline upwind Petrov-Galerkin (SUPG) method. With the developed code we investigated the detailed change of free surface shape in time during the mold filling. In the filling simulation of a simple rectangular cavity with repeating protruded parts, we find out that filling patterns are significantly influenced by the geometric characteristics such as the thickness of base plate and the aspect ratio and pitch of repeating microstructures. The numerical analysis system enables us to understand the basic flow and material deformation taking place during the cavity filling stage in microstructure fabrications.

• Transactions of Materials Processing
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• v.6 no.2
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• pp.110-117
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• 1997

Sticking behavior under the hot rolling conditions for ferritic stainless steels have been studied. Sticking, which is a phenomenon that the naked metal exposed to the surface by scale breakaway during hot rolling sticks to the roll surface, was affected by both high temperature tensile strength and oxidation resistance of the steels. A steel having higher tensile strength and lower oxidation resistance exhibits better resistance to the sticking. It is due to that higher tensile strength increases localized deformation resistance and lower oxidation resistance creates lower friction between steel and roll by forming thicker scale as a lubricant during hot rolling. So, the sticking tends to occur more severely in the order of 430J1L, 436L, 430 and 409L. The most sensitive temperature to the sticking was found to be 90$0^{\circ}C$ for all grade of steels. It was also found that the high speed steel(HSS) roll compared to the Hi-Cr roll was more beneficial to prevent sticking. Because higher surface hardness of HSS roll compared to that of Hi-Cr roll provides less nucleation sites for sticking such as scratch on the roll surface.

• Journal of Mechanical Science and Technology
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• v.17 no.3
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• pp.400-408
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• 2003

A study on the progressive inelastic deformation behavior of the 316 L stainless steel cylindrical structure with plate-to-shell junction under moving temperature front was carried out by structural test and analysis. The structural test intends to simulate the thermal ratcheting behavior occurring at the reactor baffle of the liquid metal reactor as free surface of hot sodium pool moves up and down under plant transients. The thermal ratchet load that heats the specimen up to 550$^{\circ}C$ was applied repeatedly and residual deformation was measured. The thermal ratcheting test was carried out with two types of cylindrical structures, one with plate to-shell junction and the other without the junction to investigate the effects of the geometric discontinuities on the global ratcheting deformation. The temperature distributions of the test specimens were measured and were used for the ratcheting analysis. The ratchet deformations were analyzed with the constitutive equation of the non-linear combined hardening model. The analysis results were in good agreement with those of the structural tests.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.295-298
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• 2005

High temperature deformation behavior of $\alpha\;and\;\beta$ phase of Ti-6Al-4V was investigated within the framework of a self-consistent approach at various temperature ranges. To examine the flow behavior of u-phase, Ti-7.0Al-1.5V alloy was used, whose chemical composition is close to that of the $\alpha$ phase in Ti-6Al-4V at hot working temperatures. The flow stress of $\beta$ phase was predicted by using self-consistent approach. The flow stress of $\alpha$ phase was higher than that of $\beta$ phase above $750^{\circ}C$, while the $\beta$ phase revealed higher flow stress than a phase at $650^{\circ}C$. It was found that the relative strength and strain rate ratio between $\alpha\;and\;\beta$ phase significantly varied with temperature. From this approach, the mode for grain matrix deformation was proposed as a mixed type of both iso-stress and iso-strain rate modes.

• Transactions of Materials Processing
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• v.31 no.6
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• pp.344-350
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• 2022

Extruded Mg-Bi binary alloys are known to have an undesirable bimodal grain structure containing a large amount of coarse unrecrystallized grains. Accordingly, to improve the microstructural homogeneity of extruded Mg-Bi alloys, it is necessary to promote the dynamic recrystallization (DRX) behavior during hot extrusion. An effective way to promote DRX is an increase in nucleation sites for DRX through a pre-deformation process before extrusion, such as cold pre-forging and hot pre-compression. However, the application of these pre-deformation processes increases the cost of final extruded Mg products because of an increase in energy consumption and decrease in productivity. Therefore, a low-cost new continuous process with high productivity is required to improve the microstructural homogeneity and mechanical properties of extruded Mg alloys without a drastic increase in the entire process cost. This study proposes a new extrusion method using an extrusion billet with a truncated cone shape (i.e., tapered billet) instead of a conventional extrusion billet with a cylindrical shape. When the hot extrusion of a Mg-5Bi alloy is conducted using the tapered billet, the DRX behavior during extrusion is considerably promoted. The DRX fraction and average grain size of the extruded alloy significantly increase and decrease from 65% to 91% and from 225 ㎛ to 49 ㎛, respectively. Consequently, the extruded Mg-5Bi alloy fabricated using the tapered billet has a finer homogeneous grain structure and higher tensile elongation than the extruded counterpart fabricated using the cylindrical billet.

• Korean Journal of Materials Research
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• v.9 no.9
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• pp.865-871
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• 1999

Effect of sintering condition in mechanical properties of ZrSiO\ulcorner shell molds was investigated. Number of microcrack in primary layer of the mold was maximized after preheating at $1000^{\circ}C$ for 1.5 hours. Yield strength and specific surface area of the mold were inversely proportion to sintering temperature and time. After hot deformation test at $1500^{\circ}C$ for 4 hours, molds were deformed opposite to the loading direction and backup layers were cracked along the interface between stucco and zircon slurry. Reverse deformation of the molds during hot deformation test was considered to be resulted from the difference of thermal expansion coefficient between alumina stucco and zircon slurry in primary coat, and size difference between zircon stucco and zircon slurry in backup coat.

• Korean Journal of Materials Research
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• v.11 no.2
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• pp.82-87
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• 2001

The hot deformation behavior of Ti-6Al-2Sn-4Zr-6Mo(Ti6246) alloy was investigated in both the $\alpha$+$\beta$ and $\beta$-phase fields by conducting compression tests over a strain rate range of $10^{-3}s^{-1}$ to $10^0s^{-1}$. The flow stress was increased with increasing strain rate and decreasing test temperature. The flow curves obtained at temperatures below 90$0^{\circ}C$ exhibited a flow softening. However, in the $\beta$-phase field, above 95$0^{\circ}C$, the flow stress increased monotonically with plastic strain approaching steady state values. Constitutive equations for the dependence of flow stress on strain, strain rate, and temperature were developed through the analysis of the flow curves.

• Korean Journal of Metals and Materials
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• v.46 no.6
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• pp.329-337
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• 2008

During the continuous casting of boron-bearing steel, the corner cracks on the slab are formed by deformation with low strain rate and rapid cooling at the unbending temperature within the range of 800- $1000^{\circ}C$. Especially, the rapid cooling in the corner of slab during the continuous casting leads to as corner cracking. Therefore, in this study, the hot tensile tests applied to the different cooling rates were taken into account in order to study the effect of cooling rate on the hot ductility of boron-bearing steel. The results revealed that increasing cooling rate deteriorate the hot ductility of boron- bearing steel. Rapid decreasing of the hot ductility is caused by formation of a film-like ferrite and precipitate at the austenite grain boundaries. The morphology of the precipitates in the boron-bearing steel was monitored by PTA (Particle Tracking Autoradiography) and TEM, we observed MnS and BN compound and their morphology was quite different depending on the cooling rates. When the cooling rate is increased, rodshape MnS and BN precipitates can be formed along the austenite grain boundaries. It can cause that weakening the boundary region and decreasing the hot ductility of boron-bearing steel.

• Transactions of Materials Processing
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• v.31 no.6
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• pp.365-375
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• 2022

The microstructure and high-temperature plastic deformation behavior of the modified Al-0.7Mn alloy were investigated and compared with the conventional Al-0.3Mn (Al3102) alloy. α-Al (matrix) and Al₆(Mn, Fe) phases were identified in both alloys. As a result of microstructure observation, both alloys showed equiaxed grains, and Al-0.7Mn alloy showed larger grain size and higher Al₆(Mn, Fe) fraction than Al-0.3Mn alloy. High temperature compressive tests, the deformation temperatures of 410℃, 450℃, 490℃, 530℃ and strain rats of 10^-2/s, 10^-1/s, 1/s, 10/s, were conducted using Gleeble equipment. The flow stress values of Al-0.7Mn alloy were higher than that of Al-0.3Mn alloy at all strain rates and temperature conditions. Constitutive equations were presented using the flow stresses obtained from experimental results and the Zener-Hollomon parameter. In the true stress-true strain curves of the two alloys, the experimental and predicted values were in good agreement with each other. Based on the dynamic material model, eutectic deformation maps of Al-0.7Mn and Al-0.3Mn alloys were suggested, and the plastic instability region was presented. The modified Al-0.7Mn alloy showed a wider plastic instability region than that Al-0.3Mn alloy. Based on the process deformation maps, the MPE tube parts could be manufactured through the actual extrusion process using the suggested conditions.