• Transactions of Materials Processing
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• v.22 no.5
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• pp.275-279
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• 2013

The tube hydroforming process has received much attention in the automotive industry because of its advantages compared to conventional manufacturing technologies. A wide range of products such as sub-frames, camshafts, radiator frames, axles and crankshafts are made by hydroforming process. The hydroformed parts often need to be structurally joined to other components during assembly. Therefore, these automotive parts need to be manufactured with a localized attachment flange. In this study, FE forming analyses of a part with a rectangular flanged shape was performed with Dynaform 5.5. Using the optimized conditions determined numerically, hydroforming experiments were performed. Then, the characterization of defects was analyzed. Finally, the accuracy of the optimized internal pressure condition as well as that of the initial ram position were evaluated. The results demonstrated that flanged parts can be successfully produced using the tube hydroforming process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.241-244
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• 2003

The productivity of hydroforming process can be increased by combining pre-forming process and post-forming process such as the bending, piercing and the embedding process. Therefore in this study, integrated studies on the hydro-embedding technology have been performed by analyzing the deformed mode of the tubes and the optimal process parameters. In the case of the embedding test the characteristics of the embedded parts, such as the shape of the screw tip, screw thread and shape of thread were investigated at various process conditions. To measure the clamping force between the embedded part and the tube, special measuring device was used.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2009.06a
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• pp.390-391
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• 2009

Recently, composite hollow bushings have been increasingly employed mainly from the various characteristics. Composite bushings are superior to porcelain bushings in several respects, including lighter weight, better anti-pollution and anti-explosion properties, and easer manufacturing. This paper deals with the optimal thermal fitting for improved tightness characteristics of composite bushing. Two types of composite bushings were fabricated. For optimal fitting process, it is necessary using adhesive and designed internal structure of flange and FRP tube. In this study, for improved tightness characteristics of composite bushing has prominence and interface tolerance of flange and FRP tube. From FE-SEM analysis the adhesive layers were different with interface tolerance, sample 1 and 2 which have respective about $120{\mu}m$ and $50{\mu}m$.

• Proceedings of the KSME Conference
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• 2004.11a
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• pp.1488-1493
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• 2004

The purpose of the present work is to develop a compressed air discharging system to eject a projectile from the underwater. For the flow analysis of compressed air tank, projectile ejection tube, and pipe system, the air is assumed as an ideal gas, undergoing 1-dimensional axisymmetric, compressible flow, the Fanno flow analysis was applied. The commercial Fluent code was used to solve 3-D Navier-Stokes equation of the internal flow within the valve. The dynamics of the projectile within the ejection tube was assumed 1-degree of freedom. The calculations were performed to four cases of valve opening area ratio, i.e., 25%, 50%, 75%, and 100% opening area, at both depths of 10m and 50m. The results were shown as the figures of time variation of pressure of the compressed air tank and projectile ejection tube. The velocity and distance of the projectile were also predicted.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.347-350
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• 2003

The metal forming behavior and defect formation in Ti-6Al-4V tube during hot backward extrusion were investigated. To predict the forming-defects such as shear band, inner cracks or surface cracks, dynamic material model(DMM) including Ziegler's instability criterion and modified Cockcroft-Latham fracture criterion(C-L model) were used. These models were coupled to the internal variables generated from FE analysis. The chilling effect and friction indicated a great influence on the deformation mode of the tube and the formation of surface cracks. The simulation results for the backward extrusion were compared with the experimental observations.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.642-647
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• 2007

Determination of loading conditions for tube hydroforming(THF) process that implies an amount of the increment in axial feeding and internal pressure for each step is one of the most important constituents at the process design level. On account of the fact that those design factors mentioned above are imposed simultaneously during the process, suitable loading conditions are required to obtain robust products without any failure such as buckling, necking, bursting and so on. In which, especially, bursting is well known as the most frequently occurred failure in general THF process. In this study, therefore, determination of the loading condition based on the adaptive method was carried out to obtain safe loading paths. In addition, forming limit curves are applied to evaluate the derived loading conditions by using the simulation results. Consequently, it is found that described method in this study for THF process design is useful and has a feasibility.

• Proceedings of the Acoustical Society of Korea Conference
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• 1998.06e
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• pp.247-250
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• 1998

The scattering of plane ultrasonic waves by the nuclear fuel pin of liquid metal reactor in sodium is studied. According to the internal composition in the cladding tube, the fuel pin has three cross sections, i.e. helium gas plenum, sodium-filled section, and fuel insertion section. The scattering spectra for each section of the fuel pin are different. The circumnavigating ultrasonic waves of each section are analyzed by the resonance scattering method. The whispering gallery wave modes are generated in the sodium-filled plenum section and the fuel rod insertion section with a sodium-gap. The circumferential wave modes are propagated in the cladding tube of the helium gas plenum section. The annular gap between the cladding tube and metal uranium pellet rod affects the scattering spectra. The different propagation characteristics can be utilized for the nondestructive method of detecting the unbonded area and measuring the level of the sodium-filled section of the fuel pin.

• Transactions of Materials Processing
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• v.10 no.7
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• pp.534-542
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• 2001

Tubular hydroforming has attracted increased attention in the automotive industry recently. In this study, a professional finite element program for analysis and design of tube hydroforming processes, has been developed, called HydroFORM-3D, which is based on a rigid-plastic model. With the developed program HydroFORM-3D, the hydroforming process for an automobile lower arm is analyzed and designed. The manufacturing process for a lower arm consists of tube bending, preforming, and final hydroforming. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as internal hydraulic pressure, axial feeding, and tool geometry is required. This paper describes the influences of forming conditions on the hydroforming of a lower arm by using simulation to predict strain and tube shape during bending, preforming, and final hydroforming processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.210-213
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• 2004

Based on plastic instability, analytical prediction of bursting failure on tube hydroforming processes under combined internal pressure and independent axial feeding is carried out. Bursting is irrecoverable phenomenon due to local instability under excessive tensile stresses. In order to predict the bursting failure, three different classical necking criteria such as diffuse necking criterion for sheet and tube, local necking criterion for sheet are introduced. The incremental theory of plasticity fur anisotropic material is adopted and then the hydroforming limit and bursting failure diagram with respect to axial feeding and hydraulic pressure are presented. In addition, the influences of the material properties such as anisotropy parameter, strain hardening exponent on bursting pressure are investigated. As results of the above approach, the hydroforming limit in view of bursting failure is verified with experimental results.

• Journal of the Korean Society of Visualization
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• v.11 no.2
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• pp.34-40
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• 2013

A flow visualization near submerged nozzle of solid rocket motor was conducted by experiments. A numerical simulation was also performed to reveal detailed phenomena. Radial cold flow simulating hot gas was introduced by a porous grain model which was manufactured by perforated steel plates. The grain model was mounted in high-pressure chamber which has quartz glass at the top of the grain model. From the high-speed images, a rotating vortex was observed and the two type of counter-rotating momentums were generated in numerical results. The rotating momentum was generated at the fin-slot grain because of unbalance between high-velocity flow from slots and low-velocity flow from fin-bases. As a result, roll torques can be produced by the rotating vortex tube.