• Transactions of Materials Processing
• /
• v.4 no.3
• /
• pp.267-281
• /
• 1995

Preform design is one of the critical fields in metal forming. The finite element method(FEM) has been effective in designing preforms and process sequence, for which the backward tracing scheme of the rigid-plastic FEM has been explored. In this work a program using the backward tracing scheme by the rigid-plastic FEM is developed for three-dimensional plastic deformation, which is an extension of the scheme from two-dimensional cases. The calculation of friction between workpiece and die, and handling of boundary conditions during backward tracing require sophisticated treatment. The developed program is applied to upsetting of a rectangular block and to side pressing of a cylindrical workpiece. The results of the two applications show feasibility of the program on three-dimensional plastic deformation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2000.04a
• /
• pp.35-39
• /
• 2000

Three-dimensional rigid plastic FEM is adopted to analyze the extruding-bulging process of tee tubes. Equivalent strain-rate stress distributions and the deformation characteristic in extruding-bulging process of tee tubes are revealed which provide scientific and reliable basis for correctly designing technologcial scheme and rationally selecting parameters. meanwhile some approaches for three-dimensional rigid plastic FEM are also discussed in this paper

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2000.04a
• /
• pp.96-100
• /
• 2000

It is difficult to predict material behavior of forming process because the plastic instable flow phenomenon happens in practical forming process I. e. upsetting backward extrusion piercing indentation. In view of the direct relationship between instable material flow and quality defects of the products we should find out their phenomena, In this study we introduced the plastic spin and the kinematic hardening considering the kinematic hardening constitutive equation for rate-dependent material. Also analysis of upset forging is carried out using the rigid plastic FEM with Al7075

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2004.10a
• /
• pp.347-350
• /
• 2004

In this paper, the acceleration is studied for the rigid-plastic FEM of metal forming simulation. In the FEM, the direct iteration and Newton-Raphson iteration are applied to obtain the initial solution and accurate solution respectively. In general, the acceleration scheme for the direct iteration is not used. In this paper, an Aitken accelerator is applied to the direct iteration. In the modified Newton-Raphson iteration, the step length or the deceleration coefficient is used for the fast and robust convergence. The step length can be determined by using the accelerator. The numerical experiments have been performed for the comparisons. The faster convergence is obtained with the acceleration in the direct and Newton-Raphson iterations.

• Journal of the Korean Society for Precision Engineering
• /
• v.21 no.11
• /
• pp.155-162
• /
• 2004

The volume of the metal is not changed for the plastic deformation. For metal forming simulation, rigid-plastic FEM codes are widely used. Updating geometry using Euler method in the simulation, the volume loss is occurred. In this paper, hybrid method is introduced to perform a more accurate simulation reducing computation time. In the proposed hybrid method, RK2 method is used for geometry updating at first time step and after the boundary condition of the node is changed. At the others, Adams-Bashforth or theta method is applied to update geometry. The results show that the simulations of upsetting and side-pressing can be performed within 0.02％.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.20 no.7
• /
• pp.2118-2133
• /
• 1996

A preform is designed by the backward tracing scheme of the rigid-plastic finite element method(FEM) for net-shape shell nosing components without machining after forming. The current process of the shell nosing requires cost-consuming machining to produce final products. Here, the backward tracing scheme of the rigid-plastic FEM, a novel method for preform design of metal forming processes, derives a sound preform for net-shape shell nosing product. The current process is simulated by the rigid-plastic finite element analysis to check the metal flow involved in the forming with a trial preform and its modified preform. The two preforms are found to be inadequate for net-shape shell nosing product. The first application of the back ward tracing scheme derives a preform producing a not-shape shell nosing product. The first application of the backward tracing scheme derives a preform producing a net-shape product numerically, but it is difficult to be formed economically as a preform. Thus an improved preform is designed by the badkward tracing scheme, which is suitable for net-shape manufacturing of the shell nosing components in view of economy of production and forming characteristics of the product. The preform in the current process and a modified preform are confirmed by a series of experiments and the results give the same deformation with the numerical ones. Finally the newly designed preform by the FEM was experimentally proved to be adequate in obtaining net-shape products.

• Transactions of Materials Processing
• /
• v.8 no.1
• /
• pp.108-115
• /
• 1999

In this paper, the analysis of cold forging in final state has been performed by using rigid-plastic FEM. For the analysis, the geometry and flow stress of the workpiece are required. One method to obtain the geometry is measurement of that made from experimet. To evaluate the flow stress, average effective strain is calculated from the load-stroke diagram by using energy method. The numerical test performed to show the validity of propose method. The analysis of PFIR, the precision forging of spurgear with inside relif, is performed.

• Journal of the Korean Society for Precision Engineering
• /
• v.22 no.1
• /
• pp.122-129
• /
• 2005

On the cluster system, the parallel code of rigid-plastic FEM has been developed. The cluster system, Simforge, has 15 processors and the total memory is 4.5GBytes. In the developed parallel code, the distributed data of the column-wise partitioned stiffness are stored as the compressed row storage and the diagonal preconditioned conjugate gradient solver is applied. The analysis of block upsetting is performed with the parallel code on Simforge cluster system. In this paper, the analysis results are compared and discussed.

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

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.3
• /
• pp.33-38
• /
• 2000

In process of tube spinning far shock absorber on vehicles, the selection of feed rate and rounding radius of forming roller and revolution speed of tube and forming roller, forming gap between die and forming roller are very important factors to obtain the optimal process result. In this paper, rigid-plastic FEM and UBET analysis are applied to verify effect of each factors by forming load. We can obtain the optimal conditions to prevent defects during processing.