• Transactions of Materials Processing
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• v.15 no.8 s.89
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• pp.544-549
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• 2006

In this work, we have employed the strain gradient plasticity theory to investigate the effect of material size on the deformation behavior in metal forming process. Flow stress is expressed in terms of strain, strain gradient (spatial derivative of strain) and intrinsic material length. The least square method coupled with strain gradient plasticity was used to calculate the components of strain gradient at each element of material. For demonstrating the size effect, the proposed approach has been applied to plane compression process and micro rolling process. Results show when the characteristic length of the material comes to the intrinsic material length, the effect of strain gradient is noteworthy. For the microcompression, the additional work hardening at higher strain gradient regions results in uniform distribution of strain. In the case of micro-rolling, the strain gradient is remarkable at the exit section where the actual reduction of the rolling finishes and subsequently strong work hardening take places at the section. This results in a considerable increase in rolling force. Rolling force with the strain gradient plasticity considered in analysis increases by 20% compared to that with conventional plasticity theory.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.5
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• pp.565-571
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• 2011

Because most fatigue cracks in wheel and rail take place by rolling contact of wheel and rail in railroad industry, it is critical to understand the rolling contact phenomena, especially for the three-dimensional situation. This paper presents an approach to steady-state rolling contact problem of three-dimensional contact bodies, with or without tangential force, based on the finite element method. The steady-state conditions are controlled by the applied relative slip and tangential force. The three-dimensional distribution of tangential traction and contact stresses on the contact surface are investigated. Results show that the distribution of tangential traction and contact stresses on the contact surface varies rapidly as a result of the variation of stick-slip region. The tangential traction is very close in form to Carter's distribution.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.62-65
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• 2009

There have been strong demands for micro size screw with high precision due to miniaturization and integration trends for electronic products such as Hard Disk Drives. The thread rolling process for screw manufacturing are lower unit cost, reduced material utilization, and superior mechanical properties compared to the machining process. But little work has been done on the thread rolling of micro size screw. In this paper, we investigate thread rolling process using Finite Element Analysis (FEA) and parameter study for screw manufacturing. And we also carried out compression tests to obtain the material property and to implement into the FE tool for the numerical simulation. In case that parameter of relative position oldies is half length of pitch for maintaining the continuous thread profiles, we found that shear friction factor was 0.9 during the thread rolling process using FEA. We are trying to develop the thread rolling process using the FE-simulation to manufacture screws which have been commonly produced from the industrial level fabrication at present.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.08a
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• pp.19-24
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• 2004

Symmetrical and asymmetrical rolling was performed in AA 1050 sheets. Asymmetrical rolling was carried out by using different roll velocities of upper and lower rolls. The effect of the reduction per rolling pass on the formation of textures and microstructures during symmetrical and asymmetrical rolling was studied. In order to intensify the shear deformation, symmetrical and asymmetrical rolling was carried out without lubrication. The strain states associated with rolling were investigated by simulations with the finite element method (FEM). A fairly homogeneous residual shear strain throughout the sheet thickness was observed after asymmetrical rolling. Symmetrical rolling with a high friction gave rise to a strong net shear strain gradient in the sheet thickness.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.134-137
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• 1998

Caliber design in bar and rod rolling depends on the designer's experience, which in general is acquired through costly trial-and-error process. As a prerequisite for developing a scientific approach to caliber design, we present a finite element model to simulate 3-D deformation of bars and rods occurring in multi-pass sequence. The results are compared with measurements obtained from POSCO for to assess the solution accuracy. The comparison shows that the simulation results agree well experiments.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.08a
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• pp.313-319
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• 1999

The development of deformation texture in FCC polycystalline metals during rolling was simulated by the finite element analysis using a large-deformation, elaatic-plastic, rate-dependent polycrystalline model of crystal plasticity. Different plastic anisotropy due to different orientation of each crystal makes inhomogeneous deformation. Assuming plane strain compression condition, the simulation with a high rate sensitivity resulted in main component change from Dillamore at low rate sensitivity to Brass component.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.52-55
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• 2000

Investigated via a series of finite element process simulation is the effect of diverse process variables on some selected non-dimensional parameters characterizing the strip in hot strip rolling. Then on the basis of these parameters an on-line model is derived for the precise prediction of roll and roll power. The prediction accuracy of the proposed model is examined through comparison with predictions from a finite element process model.

• Journal of Advanced Marine Engineering and Technology
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• v.35 no.2
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• pp.244-251
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• 2011

Pipe rolling process using the planetary rolling mill for AISI 304 stainless steel has been studied by using finite element method. Mannesmann method using three-roll is applied to this rolling process. Commonly, rolling process has started from the cold working and finished to the hot working. This rolling process has more advantage that make reduction of process and cost than existing extrusion process. This process includes various and complex process parameters. Each of the process parameters affects forming result. Therefore, all of the process parameters should be considered in FEA. In this study, possibility and productivity of forming pipe for AISI 304 stainless steel had been investigated. Also, preheating process and variations of rotation velocity and product thickness were considered in FEA. Rolling process for AISI 304 stainless steel pipe was successfully simulated and it should be useful to determine optimal rolling condition.

• Transactions of Materials Processing
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• v.15 no.7 s.88
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• pp.479-484
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• 2006

The evolution of strain states and textures during rolling with various conditions was investigated by finite element method (FEM) simulations and measurements of rolling textures. Symmetrical rolling with a high friction gives rise to a strong variation of shear strains in rolled sample leading to the formation of texture gradients throughout the thickness layers. A small variation of shear strains during rolling with a well lubrication condition leads to the formation of a fairly homogeneous rolling texture throughout the sheet thickness. During asymmetrical rolling, a proper control of rolling parameters provides the evolution of a fairly homogeneous shear texture throughout the whole sheet thickness.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.11
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• pp.1437-1443
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• 2011

Thick plates produced by the rolling process are used as the basic elements of ship structures. In this paper, we present a setup model for controlling the asymmetric factors causing plate bending in the width direction during plate rolling. A series of three-dimensional finite element analyses is conducted to predict the relationship between various asymmetric factors and plate bending. The setup model is developed by performing regression on the relationship to produce linear equations with several nondimensional parameters. The setup model is verified with a pilot rolling test in which variations in thickness and temperature differences in the width direction exist. The results show that the bending curvatures predicted by the model are in fairly good agreement with the measured results for those asymmetric factors.