• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.8
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• pp.1876-1888
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• 1995

In this paper, glass surface-mat reinforced epoxy(G.S.R.E.) is developed, It is assured that the material(G.S.R.E.) can be used as photoelastic model material and it satisfy with the required properties of photoelastic model material. Therefore, the material can be used as model material of transparent photoelastic experiment when we analyze the stress distributions of transversely isotropic material by photoelastic experiment. When we use G.S.R.E. as photoelastic experiment model material, we had better use the G.S.R.E. which fiber volume ratio is less than 0.7% in the high temperature(stress freezing method) and than 1.74% in the room temperature. Relationships between stress fringe value and elastic modulus in transversely isotropic material are developed in this paper, it is assured by experiment that they are established in the room temperature or in the high temperature. Therefore we can obtain stress fringe value or elastic modulus from the relationships between stress fringe value and elastic modulus.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.430-438
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• 2002

This paper suggests the new technology to control metal flow in orther to change of the cold forging from conventional deep drawing forming. This technology can be summarized the complex forming, which consists of bulk forming and sheet forming, and multi-action forging, which be performed double action press. The proposed technology is applied to hub clutch model which is part of auto-transmission for automobile. The purpose of this study is to investigate the material flow behavior of hub clutch through control the relative velocity ratio and the stroke of mandrel and punch using the flow forming technique. First of all, the finite element simulations are applied to analyse optimal process conditions to prevent flow defect(necking defect etc.) from non-uniform metal flow, then the results are compared with the plasticine model material experiments. The punch load for real material is predict from similarity law. Finally, the model material experiment results are in good agreement with the FE simulation ones.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.11a
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• pp.1-12
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• 2001

In cold forging of piston-pin for automobile parts, the flow defect appears by the dead metal zone. This appearance evidently happens in products with a thin piercing thickness for the dimension accuracy and the decrease of material loss. The best method that can prevent flow defect is removing dead metal zone. The purpose of this study is to investigate the material flow behavior of forward-backward extruded piston-pin through the relative velocity ratio and the stroke control of upper moving punch & container using the flow control forming technique. The finite element simulations are applied to analyse the flow defect, then the results are compared with the plasticine model material experiments. Finally, the model experiment results are in good agreement with the FE simulation ones.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.7
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• pp.1366-1375
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• 2002

In cold forging of piston-pin for automobile parts, the flow defect appears by the dead metal zone. This appearance evidently happens in products with a thin piercing thickness for the dimension accuracy and the decrease of material loss. The best method that can prevent flow defect is removing dead metal zone. The purpose of this study is to investigate the material flow behavior of forward-backward extruded piston-pin through the relative velocity ratio and the stroke control of upper moving punch & container using the flow control forming technique. The finite element simulations are applied to analyse the flow defect, then the results are compared with the plasticine model material experiments. The model experiment results are in good agreement with the FE simulation ones.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.2
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• pp.285-299
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• 1993

The objective of the present study is to analyze material flow in the metal forming processes by using computer simulation and experiment with model material, plasticine. A UBET program is developed to analyze the bulk flow behaviour of various metal forming problems. The elemental strain-hardening effect is considered in an incremental manner and the element system is automatically regenerated at every deforming step in the program. The material flow behavior in closed-die forging process with rib-web type cavity are analyzed by UBET and elastic-plastic finite element method, and verified by experiments with plasticine. There were good agreements between simulation and experiment. The effect of corner rounding on material flow behavior is investigated in the analysis of backward extrusion with square die. Flat punch indentation process is simulated by UBET, and the results are compared with that of elastic-plastic finite element method.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.374-383
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• 1999

To determine the flow stress of semi-solid materials, a new combined method has been studied by experimental and analytic technique in the current approach. Using backward extrusion experiment and its numerical analysis, the characterization scheme of semi-solid materials according to the change of initial solid volume fraction has been proposed. Because that solid volume fraction is sensitive to temperature change, it is required to precisely control the temperature setting. Model materials can guarantee the establishment of material characterization technique from the noise due to temperature change. Thus, clay mixed with bonded abrasives was used for experiment and the change of initial solid fraction was copied out through the variation of mixing ratio. Upper bound method was adapted to increase in efficiency of the calculation in numerical analysis and new kinematically admissible velocity field was employed to improve the accuracy of numerical solution. It is thought that the material characterization scheme proposed in this study can be applied to not only semi-solid materials, but also other materials that is difficult to obtain the simple stress state.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.5
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• pp.1190-1201
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• 1995

Photoelastic experiment has been restricted by three significant problems such as the problems of modeling for a complicated body, of development of experimental model material, and of residual stress in photoelastic specimen. The residual stress in photoelastic model materials is caused by molding, cutting and time effects, etc.. Especially, large residual stress exists on the interface of photoelastic model material for bi-material. Small residual stress occurred in the photoelastic model materials is usually neglected in the photoelastic experiments. But the residual stress provides some errors in the results of photoelastic experiments. In this paper, the stress optic law which can be effectively applied to the phtoelastic model materials with residual stress is developed. By using this stress optic law, we can obtain good results from isochromatic fringe patterns of photoelastic experiment specimen in which residual stress are involved. The stress optic law can be applied to obtain good results of photoelastic experiment from composite materials or bimaterials.

• Transactions of the Korean Society of Mechanical Engineers
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• v.12 no.1
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• pp.8-18
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• 1988

In the composite structures or the concrete structures, to analyze stress concentration factor, stress distributions and fracture mechanics of them under forces by photoelastic experiment, it is natural that to develope photoelastic model material for them is surely necessary. Thus, the orthotropic photoelastic model material for the transparent type photoelastic device was developed in the paper, it is called Copper Fiber Epoxy Composite and abbreviated as E.F.E.C. It was found that C.F.E.C. developed in this paper was satisfied with the properties of photoelastic model material that the photoelastic model material should have and that C.F.E.C. had completely properties of composite material. It is thought that C.F.E.C. can be applied to both medical engineering for modeling biological tissue and to the aerospace industry as orthotropic photoelastic material.

• Journal of Mechanical Science and Technology
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• v.17 no.11
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• pp.1674-1681
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• 2003

Photoelastic experiment has two significant problems. The first problem is manufacturing a model specimen for complicated shapes of structures. The second problem is residual stress contained in the photoelastic model material. In this paper, the stress optic law that can be effectively used on photoelastic model materials with residual stress is developed. By using the stress optic law as developed in this research, we can obtain good results in photoelastic experiments using model material in which residual stress is contained. It is assured that the stress optic law developed in this research is useful. Therefore, it is suggested that the stress optic law considering residual stress can be applied to the photoelastic experiment for the stress analysis of the composite materials or bi-materials in which the residual stress is easily contained.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.12
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• pp.142-149
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• 2002

In this paper, the metal forming process is caused of rise of the unit cost of production in increase of the lead-time and cost because of manufacturing final product through a few the number of processes. Flow control complex forming is proposed to put into formulation in order to apply cold forging from conventional approximate similarity theory, and the forming loads of the real material(AISI 1008) can be calculated by put at the new similarity formula the load by plasticine model material experiment through hub clutch. In order to reduce lead-time and cost the technology is used to manufacture with lower die of this product. By the application synthetic resin as the raw material, it is have the merit such short lead-time, low cost, good surface finish etc., as compared with the machine work.