Papers by Author: D.H. Jang

Abstract: The yield criterion describing asymmetric behavior of powdered metal compacts in tension and compression is introduced by modifying that used for sintered powdered metals. The plasticity theory related to the modified yield criterion is reviewed and summarized for a powdered metal compact. The constitutive equation is applied to the variational principle and its discritization is also introduced. Axisymmetric die pressings with copper powders were performed to see the deformation mechanics of hollow three-level parts. The simulation includes two different types of multiple-motion tooling compaction of a Class IV part of hollow three-level component. Predictions are made for density distributions, load-stroke relationships, average density as function of height, pressure distributions along the die-walls and punches, average compact densities at each level, and energy consumption for each pressing. The information from simulation can be used to synthesize the various punch motions in a multiple action tooling system.

Abstract: Numerical simulations are applied to investigate the simultaneous radial-forward extrusion process in a combined extrusion such as subsequent radial-forward extrusion after radial extrusion. Design factors for the process such as gap height, deflection angle into annular gap and frictional condition are employed in the analysis. The analysis is focused to see the influence of design factors on the maximum force requirement for the forming process. One of the selected simulation results is compared with the experiments in terms of load-stroke relationships. The pressure distributions exerted on the die-wall interfaces are also investigated to reveal if the tooling system is safe, especially the die set. The plastic stress-strain relationship is derived analytically from the material constants used in elastic deformation analysis. It is revealed from the simulation results that the influence of the deflection angle on the maximum force requirement for the process is greatest among design parameters. AA 6063 alloy is selected as a model material for the analyses in this study.

Abstract: A frictional contact model is adopted for the analysis of conventional solid rivet setting. Material properties for the selected plates and rivets are obtained from analytical method using elastic constants and tensile strengths for each material. Rigid- and elasto-plastic models are selected for process analysis in this paper. Process variables are selected to investigate the effect of variables on the successful rivet setting and servicing in any structure as force transmitting member. Major variables in riveting process are material variables such as material properties and geometrical variables, which are dimensions of head, shank, and blank diameters. Analysis in this study is concentrated on the influence of variety of materials and of shank dimensions on the contact area after rivet setting, i.e. after forming process of rivet head. Soft and hard materials are selected as mother materials to investigate how the selection of material influences on the riveting process in quantitative manner. The geometry of head is closely investigated through simulation in terms of contact status, i.e. contact area between rivet head and mother material, which would affect the snap fit joint by riveting.

Abstract: A finite element method for the compaction process of metallic powder is introduced in the present work. Basic equations for the finite element formulation are summarized. A yield criterion, which is modified by describing asymmetric behavior of powder metal compacts, is introduced and applied to various classes of powdered metal compaction processes. Three material parameters are involved in the yield function and determined from the behavior of sintered powder compacts as a function of relative density. The FEM simulation includes single-action and double-action pressings of solid cylinders as well as cylindrical rings of relatively long parts (Class II parts). The compaction process for multi-level flanged components (Class III and Class IV parts) is also analyzed. The predicted results from simulations are summarized in terms of density distributions within the compacts and pressure distributions exerted on the die-wall interfaces, and also in terms of effectiveness with increased relative motions with in the compacts and the effect of various compaction schemes of combination of punch motions. Results obtained in the multi-level compaction process are discussed in terms of average relative density distributions at each height.

Abstract: The cold forging processes of automobile parts such as piston-pin, valve-spring retainer(VSR) and power-assisted steering part (PAS) are analyzed by the rigid-plastic finite element method. The results of the simulation on the piston-pin are summarized in terms of the strain distribution and load-stroke relationship. Based on the analysis on the current processes of VSR and PAS, the new novel processes for improving the conventional process sequences are designed. As a design criterion, the improved processes satisfy the new condition such as an initial billet size, the production time and the limit value of forming load and pressure etc. The present simulation results and the newly developed process gave rise to an improvement in manufacturing processes for cold-forged automobile parts. Furthermore, the numerical analysis for the processes in this study provides a new design concept for forming processes and a basis for the selection of forging equipments.

Abstract: The dissimilar channel angular pressing (DCAP or CCSS) based on the equal channel angular pressing (ECAP) was numerically modeled and analyzed by means of a rigid-plastic two-dimensional finite element method. Multi-pass rolling is performed in two different manners; the feeding direction of samples into the DCAP-channel is maintained in Route A and the feeding direction is reversed in the Route B. The deformation of AA1100 sheets during the DCAP process comprises three distinct processes of rolling, bending and shearing. The shear deformation of an amount of 0.5 was concentrated at the corner of the DCAP-channel where the abrupt change in the direction of material flow occurred. Because differences in the shear deformation in Route A and Route B led to the different strain states throughout the thickness of the aluminum sheet, the strain history in the DCAP-channel was analyzed in various thickness layers by the shear and effective strain components.