In this study, the finite element analysis of AA6061 wheel forging processes over hot working range is performed and a thermo-viscoplasticity theory applicable to hot forging is applied for simulation. Aluminum alloy has frequently been utilized to manufacture automobile and aircraft parts due to its various advantages such as lightness, good forgeability, and wear resistance. Several forging conditions are applied to the simulation, such as die speeds, rib thicknesses, and depth of die cavity. The effectiveness of the simulation results is summarized in terms of metal flow, strain distributions, temperature distributions, forging load, which are essential to over all process design.

In the two-dimensional Finite Element Method for forming simulation, mesh generation and remeshing process are very significant. In this paper, using the modified splitting mesh generation algorithm, we can overcome the limitation of existing techniques and acquire mesh, which has optimal mesh density. A modified splitting algorithm for automatically generating quadrilateral mesh within a complex domain is described. Unnecessary meshing process for density representation is removed. Especially, during the mesh generation with high gradient density like as shear band representation, the modified mesh density scheme, which will generate quadrilateral mesh with the minimized error, which takes effect on FEM solver, is introduced.

In the present work, rigid-plastic continuum elements employing the shape change and anisotropic effects are derived for the purpose of applying more realistic blankholding force condition in three-dimensional finite element analysis of sheet metal forming process. In order to incorporate the effect of shape change effectively in the derivation of finite element equation using continuum element for sheet metal forming, the convected coordinate system is introduced, rendering the analysis more rigorous and accurate. The formulation is extended to cover the orthotropic material using Hill's quadratic yield function. For the purpose of applying more realistic blankholding force condition, distributed normal and associated frictional tangent forces are employed in the blankholder, which is pressed normal and associated frictional tangent forces are employed in the blankholder, which is pressed against the flange until the resultant contact force with the blank reaches the prescribed value. As an example of sheet metal forming process coupling the effect of planar anisotropy and that of blankholding boundary condition, circular cup deep drawing has been analyzed considering both effects together.

Buckling analysis of thin compressed beam has been carried out. Pre-buckling and post-buckling are simulated by finite element method incorporating with the incremental nonlinear theory and the Newton-Raphson solution technique. In order to find the bifurcation point, the determinent of the stiffness matrix is calculated at every iteration procedure. For post-buckling analysis, a small perturbed initial guess is given along the eigenvector direction at the bifurcation point. Nonlinear elastic buckling and elastic-plastic buckling of cantilever beam are analyzed. The buckling load and buckled shape of the two models are compared.

The coiling station of ISP coil box is an equipment that winds a hot bar rolled at reduction unit into a coil without mandrel. In the coiling process, the roll gap of the bending unit is a significant one of several factors that influence bar coiling. To obtain a good bar-coil, the roll gap must be set appropriately according to the bar thickness. In this study, with 2-dimensional isothermal elastic-plastic finite element method, authors investigated influence of the change of the roll gap on the initial coiling shapes and the formed inner diameters of coils. Based on finite element analysis, authors proposed the appropriate roll gap according to the bar thickness to be able to wind a hot bar. The inner diameters of coils by results of analysis comparatively agreed with coling operation conducted in plant.

The governing functional in plastic deformation has to satisfy the incompressible condition. This incompressible condition imposed on the velocity fields can be removed by introducing either the Langrange multiplier or the penalty function into the functional. In the study two-dimensional rigid plastic FEM programs using by Lagrange multiplier and penalty function are developed. A compression of cylinder and a spike forging are simulated to compare the data of loads, local mean stresses and reductions of volume.

The kinematically admissible velocity field is developed for the eccentric extrusion of circular shaped products. The curving of product in extrusion is caused by the difference of the linearly distributed longitudinal velocity on the cross-section of the workpiece at the dies exit. The results of the eccentric extrusion by upper bound analysis show that the curvature of product increases with the increase in eccentricity of gravity center of the cross-section of workpiece at dies entrance from that of the corss-section at the dies exit end. By the DEFORMTM-3D analysis, the curving of circular shaped product in extrusion is changed by the eccentricity, die land length and the die length. The result of the analysis by DEFORMTM-3D software shows that the curvature of circular shaped product increases with the eccentricity. The two analysis and one experiment show the curving phenomenon in eccentric extrusion process.

The kinematically admissible velocity field is developed for the analysis of the curving of an eccentric extrusion. The curving of product in extrusion is caused by the difference of the linearly distributed longitudinal velocity on the cross-section of the workpiece at the dies exit. The result of the analysis show that the curvature of product increases with the increase in eccentricity of gravity center of the cross-section of the workpiece at the die entrance from that of the cross-section at the die exit. It also increase with the die land dimension. By the DEFORMTM-3D analysis, the curving of T-shaped product in extrusion is changed by the eccentricity, die land length and the friction constant. The result of the analysis by DEFORMTM-3D software shows that the curvature of circular shaped product increases with the eccentricity. The two analysis and one experiment show the curving phenomenon in eccentric extrusion process.

The multistage precision forming process for aperture of electronic guns consists mainly of drawing and swaging operations. The multistage forming sequence is analyzed in view of production industry, and based on the industrial investigation. The processes are simulated by the finite element code MARC. The elastic recovery, strain and stress distribution, and the die forces are summarized.

The governing functional in plastic deformation has to satisfy the incompressible condition. This incompressible condition imposed on the velocity fields can be removed by introducing either the Langrange multiplier or the penalty function into the functional. In this study two-dimensional rigid plastic FEM programs using by Langrange multiplier and penalty function are developed. A compression of cylinder and a spike forging are simulated to compare the data of loads, local mean stresses and reductions of volume.

Computer simulations and test trials are carried out to get the optimal conditions about the stamping die design of the tailor laser welded automotive door inner. Firstly, the stamping process including gravity deflection, bead calibration, binder wrap, forming and spring back, are analyzed by the computer simulation. The results of simulation shows good correspondance with those of test trial under the same conditions. The variables of parametric study which will be investigated in the simulation and test trials, are determined form the results of the first run. The formability under the various conditions is evaluated, which are the initial postion of blank, blank holding force, corner radius and the shape of drawbead. Finally, well controled sound product without fracture, wrinkling and excessive weldline movement is obtained.

In this paper, the forming limits of laser welded blank sheets are introduced, obtained from a tensile test and a hemispherical dome punch test. Especially, the forming limit diagram(FLD) on the heat affected zone with a width 2.54mm is emphasized. Also, the experimental experiences in finding specific strain conditions are discussed.

In this study, an elasto-plastic finite element code, ESFORM, was developed to analyze sheet stamping processes. A formulation of 4-node degenerated shell element was implemented in the code. Workpiece materials were assumed to have planar anisotropy, and governed by associated flow rule. Explicit time integration method was employed to save computation time and reduce the required computer memory. Penalty method was used to describe interface behavior between workpiece and rigid die. Deep drawing of square cup and front finder stamping processes were simulated by ESFORM>

The split Hopkinson bar technique is the most widely used method to study material behavior at high strain rate deformation. In the present paper, a torsional Hopkinson bar for testing thin-walled tube specimens at high strain rate is described. From the experiment of aluminum 6061, dynamic stress-strain relationship can be obtained and dynamic result is compared with static one.

The Jonhnson-Cook constitutive relation has been used in dynamic plasticities. The constants of the Jonhson-Cook relation of sheet metals for an autobody is not known yet. In this paper, the material properties of SPCEN, SPCC and SPRC in the high strain rate states have been acquired. A new tension split Hopkinson bar was used in high speed tensile tests of sheet metals. The experimental results acquired from the apparatus are used to determine the constants of Johnson-Cook constitutive relation of sheet metals. This results can be used to analysis of crashworthness.

Design of a weld line in a tailor welded blank is indispensable for good manufacturing of stamped parts as assigned, since the intial weld line is distorted severely with forming. The initial weld line has to be determined such that desired weld line in a formed part can be obtained. The initial weld line was predicted by inverse finite element analysis from the desired weld line in a formed part. The inverse approach is applied to the cylindrical and square cup drawing with tailor welded blanks. The applications demonstrates that the approach is useful for design of weld line of tailor welded blank.

Since the modified membrane element has the same external appearance as the ordinary membrane element, it is not able to apply the thickness variation of sheet metal in the blank holder to the contact treatment and the equally distributed blank holding force should be inevitably imposed on sheet metal along the periphery regardless of the contact status. But sheet metal does not contact with the blank holder at the periphery, nor the blank holding force is distributed uniformly along the boundary. To impose the blank holding force properly, the scheme is improved so that the blank holding force at each node imposed on sheet metal is dependent on the calculated thickness derivation and a state of equilibrium with the total blank holding force. The validity of the improved scheme is demonstrated with the simulation of cylindrical and rectangular cup deep drawing.

Membrane panels for LNG(Liquid Natural Gas) tank are formed to corrugared ones by press forming. The environment of LNG tank is so severe that the service temperature is -162$^{\circ}C$ and the room temperature is 20$^{\circ}C$. The thermal deformation derived by the severe temperature change is absorbed by the corrugations of the membrane panels. In this paper the formability of stainless steel membrane panel is examined by the finite element analysis. Two corrugated shapes are suggested, and analyzed to obtain a sound absorption performance of the thermal distortion. Also the design considers forming characteristics and economy of production.

The surface deformation of shadow mask was studied by the experiments and numerical analysis for process improvement and delet of the stabilizing process in the shadow mask manufaturing line. To inverigate the thermal deformation of shadow mask with and without stabilizing process mask, data of spring strength, frame flatness, frame magnetic force and a mask surface curvature were measured. The tube characteristics of two kind of shadow masks were also investigated.

The major object in this report is the curvature prediction of front end downward bending in plate rolling. Because of relations front end shape and curvature in plate, many simulations were carried out to obtain empirical model. Simulation conditions, for example the position and the size of bottom stripper or roller table etc., were limited to the POSCO conditions. Though the result in this report can be applied to the special case, the tendency of this result is similar to the many cases. So the empirical model equation can be improved or expanded to many simulation conditions.

Recently, hot rolling oil lubrication technology is required to face with the new environments such as the rapid introduction of high wear resistent high speed steel roll the development of continuous hot rolling technology. In the hot strip mill, according to rolling and quality required conditions are constrict, Roll material of hot rolling finishing stand is changing Hi-Cr Roll to High Speed Steel [HSS] Roll. The problem of HSS Roll of roll force and strip scale defects are increasing in hot strip mill, So we have tested HSS Roll in hot rolling simulator as rolling condition, rolling speed, draft, hot oil concentration. To reduce roll force and prevent scale defects. We get some merit rolling force, rolling torque, roll wear reduction, roll and strip surface roughness and hot rolling critical oil concentration 0.4%. Finally we are going to investigate the effect of hot rolling oil of on rolling with HSS Roll.

Bellows are suggested as energy absorbing elements for automotive steering systems. A metallic bellows has nearly constant axial collapse load which is desirable as an energy absorbing element for a steering column. Axial collapsability and bending flexibility of bellows can be utilized to reduce upward tilting and backward displacement of steering columns in the early stage of high speed crash. Since bending flexibility of bellows has negative effects on the vibration characteristics of steering columns it is necessary to maximize the first natural frequency of a bellows while maintaining its plastic bending flexibility and axial collapse load. An effort is made to attain optimum design of bellows based upon the Taguchi method. A general guideline for design of bellows is suggested.

During crash of a vehicle a major part of the kinetic energy of the driver is absorbed by a steering system. The deformation characteristics of the steering system has significant effects on the injury of the driver. A part of the energy is absobed by the steering wheel and another part by the collapsable steering column. It is believed that the structure of the steering wheel has an important effect on the injury of the driver. A design criterion is suggested for steering wheels for maximum protection of drivers. Taguchi method is used to obtain the effects design parameters.

CFM(Cast Forge Method) is widely used in manufacturing industry to produce aluminium parts with good mechanical properties and low production cost. CFM is the process which produces a final products by forging from the initial billet by casting. The study on this paper covers the automatic design method which finds a pertinent shape for initial billet using Fast Fourier Transform, low-pass frequency filtering and FEM simulation of the nonisothermal forging process by DEFORM. These works will give us an information to enhance the low strength of a aluminium casting.

An automated surface-strain measuring system is developed in the present study, which consists of the hardware to capture and to display digital images and the software to calculate the 3-D informations of grid points. The software is implemented using the image processing technique, and includes a program for the camera calibration and the post-processor to display the strain distribution. An LDH(limitting dome height) test specimen is measured its surface-strain as an application of the present system.

This paper presents a method for measuring and analyzing strains in sheet metal forming by stereo vision system. A better understanding and evaluation of the formability can be achieved by analyzing stain distribution in deformed sheet metals. By means of image processing technique, it is possible to get strain distribution efficiently. For measuring strain automatically and accurately, algorithms for camera calibration, grid detection, stereo matching and strain analysis has been developed and verified by experiments with GUI(Graphic User Interface).

The investigation deals with the process design in cold rolling mill of electric plant. In this study, multiple objective optimization is conducted by a genetic algorithm, where the fitness values are evaluated on the basis of one - dimensional model of flat rolling. The approach is applied to the determination of the process conditions which are optimal with regard to minimization of roll power and maximization of productivity.

In this paper the tool geometry of the PSS test were optimized in order to assure the reliability of the test. Considering many factors for optimization of the tool geometry, computer-simulation technique using three-dimensional finite element method(FEM) was used. Three design variables -the punch length, punch crown and punch corner radius- are chosen to be optimized according to the Taguchi's experiment technique with the L9 orthogonal array. The optimum condition to ensure the plane strain mode over the overall area of the specimen was clarified. Moreover the simulation results are confirmed by experiment.

The die wear is one of the main factors affecting die accuracy and tool lifetime. It is desired to reduce die wear by developing simulation method to predict wear based on process parameters, and then optimize the process. Therefore, this paper describes disign methodology of preform for minimizing wear of finisher die in multi-stage cold forging processes. The finite element method is combined with the routine of wear prediction and the cold forging processes. The finite element method is combined with the routine of wear prediction and the cold forging process is analyzed. In order to obtain preform to minimize die wear, the FPS algorithm is applied and the optimal preform shape is found from iterative deformation analysis and wear calculation.

With the development of computers, CAD(Computer-Aided-Design)/CAM (Computer-Aided-Manufacturing) has been increasingly applied to manufacturing processes to increase productivity, and recently studies of expert systems, a field of Al(Artificial Intelligence), are being carried out to assist process designs. In this study, an expert system for the process design of ball stud was developed. The adequacy of the developed system was examined through comparisons with actual blueprints and verification by experts. The designed process data was saved in dxf file format for transfer to AutoCAD, from which prototype process blueprints were obtained.

The conventional closed-die forgings had been applied to the forging of spur gears. But the forgings require high forging-pressure. In this paper, new precision forging technology have been developed. The developed technology is two steps forging process. Good shaped products are forged successfully with lower forging-pressure than those of conventional forging

During a compression molding of continuous fiber reinforced composites, the separation of matrix and fiber is caused by the flow of the molding process. As the characteristics of the products are greatly dependent on the separation, it is very important to clarify the separation in relation to molding condition, degree of needle punching number on the degree of nonhomogeneity are studied.

Static restoration during hot interrupted deformation of 304 stainless steel was studied in the temperature range from 900 to 1100$^{\circ}C$ under various strain rate of 0.05∼ 5/sec and pass strain of 1/4∼3 times peak strain. The static restoration was dependent on the pass strain, deformation temperature and strain rate. Fractional softening(FS) values increased with increasing strain rate, deformation temperature and pass strain. Recystallization kinetics was well explained by the Avrami equation and the time for 50% recrystallization was evaluated using equation of t0.5=2.01${\times}$10-10$\varepsilon$-.156$\varepsilon$ -0.81Dexp(196.66/RT)

The deformation characteristics of 50kgf/$\textrm{mm}^2$ grade steels were studied numerically and experimentally to investigate the effects of the size, shape, distribution and volume fraction of the second phase on mechanical properties. Flow curves of ferrite calculated by Tomota's experimental equation was modified to take into account yield point phenomena of steels. The predicted tensile properties by modified Tomota's method were in good agreements with measured data.

The texture of a 0.25mm dia high-carbon(0.73%) steel wire made by drawing the patented and brass coated 1.4mm wire through 22 dies with a die-angle of 12$^{\circ}$has been measured. The ideal fiber texture was obtained in the center layer, while the circular texture and the near fiber texture having {111}<110> and weak {112}<110> components were obtained in the intermediate and surface layers, respectively. The circular texture was approximated by {110}<110> plus {110}<114>. The texture could be predicted by the Taylor-Bishop-Hill theory coupled with FEM for deformation.

Aluminum alloy sheets are considered as one of the high potential substitutes for steel sheets considering weight reduction of automobiles. However, aluminum alloy sheets have drawbacks in higher prices and inferior formability compared to steel sheets. In order to achieve good deep drawability, it is imperative to obtain well developed {111} texture which gives rise to higher plastic strain ratio. It is difficult to obtain this texture from conventional rolling and annealing processes. Therefore, an unconventional rolling process which enhances shear deformation has been experimentally studied to obtain the well developed {111} texture, which in turn gives rise to a substantial increase in plastic strain ratio.

The mechanical properties of Ti-6Al-4V greatly vary for changes of microstructures. Therefore, when manufacturing components with this material, it is important to understand the influence of process parameters to the resulting microstructures. In the present investgation, it was attempted to relate the process parameters with the microstructures in a hot forged Ti-6Al-4V disk. The investigation was carried out by a rigid thermo-viscoplastic FEM analysis, flow stress measurements and microstructure studies. It was found that the dynamic recrystallization would hardly occur in this material and that variations of strain, strain rate and temperature of several locations in the disk were below the assumed dynamic recrystallization zone. These findings confirmed the experimental obervations that the microstructures in the disk were only deformed without being recrystallized.

The development of rolling texture is dependent on the various rolling condition. And the geometry of rolling gab and the friction between rolls and rolled material mainly affect the type and sharpness of texture inhomogeneity through thickness. In order to follow the effect of geometry and friction various strain/pass and lubrication condition were applied during cold rolling. In this investigation various strain/pass and lubrication were applied during cold rolling in order to follow the effect rolling gap geometry and friction. More high 1/h was, more weak the ${\beta}$-fiber was and in the condition of l/h > 5 {001}<110> shear texture developed. In adition, rolling without lubrication enhanced the shear texture.

Hot workability of SiCp/AA2024 composites reinforced with different vol. % of SiCp reinforcements (0, 5, 10, 15, 20, and 30 vol. %) was investigated by hot torsion tests. Hot restoration of the composites was studied from the flow curves and deformed microstructures. Dynamic recrystallization (DRX) was occurred in all the composites during the hot deformation at 370-43$0^{\circ}C$ under a strain rate of 1.0/sec. Also, the flow stress of the composites increased with increasing the SiCp reinforcement vol. % and the difference of flow stress between the composites decreased with increasing the deformation temperature.

This paper presents the prediction of microstructure of Inconel 718 disk forgings. The experiments are carried out to examine the recrystallization ratio and grain growth in the forgings. In the experiments, cylindrical billets are forged by two operations with variations of forging temperature and reduction ratio of deformation. Also the finite element program, developed here for the prediction, is used for the analysis, and the results are compared with the experimental ones. It is noted that the comparison appears in sound agreement.

In Ni and Zn plating, microstructure and corrosion behavior of electrodeposits with various electroplating condition were investigated. Optical microstructure, SEM images and polarization curves of electrodeposits are different with plating time and temperature.

A series of load relaxation tests was performed to determine stress-strain rate curves at high temperatures. Constitutive parameters of GBS and GMD were evaluated from the curves using the recently proposed inelastic deformation theory. Tensile tests and Microsturcture investigations showed deformation behavior as the relaxation test results predicted.