Choon Man Lee

An upper-bound solution for axisymmetric extrusion of composite rods through curved dies

Abstract The study is concerned with an analysis of forward extrusion of composite rods through curved dies. A kinematically admissible velocity field is derived by assuming proper streamlines and applying the flow function concept to each material region of plastic deformation. Two kinds of flow functions are chosen in order to compare the effect of the choice of the flow functions. The effect of work-hardening is incorporated approximately by calculating the strains at the exit of both materials. The upper-bound method is then employed to determine the extrusion pressure for various process variables. The experiments are carried out with commercially pure aluminum and copper billets for various reductions of area and cone angles at room temperature. The experimental results are then compared with the theoretical calculations. The comparison shows that the second-order flow function is in better agreement with the experimental observation both in extrusion loads and in deforming regions.

A three-dimensional steady-state finite element analysis of square die extrusion by using automatic mesh generation

Steady-state finite element analysis is made for three-dimensional hot extrusion of sections through square dies by using an automatic mesh generator which can generate three-dimensional meshes by shifting two-dimensional meshes. In industrial practice, the design of extrusion dies is still an art rather than science, especially for complicated profiles, because the die design for a new extrusion is developed from previous experience and in-plant trials. The objective of this study is to develop a steady-state finite element method for hot extrusion through square dies, and to provide a theoretical basis for an optimal die design and process control for the extrusion technology. In the present investigation, steady-state assumption is used for both the analyses of deformation and temperature. The analysis of temperature distribution includes heat transfer, and is carried out by decoupling from the analysis of deformation. Convection link element is adopted for the heat transfer analysis between the billet and the container, and also between the billet and the die. Computations are carried out for solid and hollow extrusion of several sections. The present method of analysis has been shown to provide good results comparable with the non-steady-state method with reduced computation time. Distributions of temperature, effective strain rate, velocity and mean stress are discussed for effective design of an extrusion die.

Evaluation of Cutting Force and Surface Temperature for Round and Square Member in Laser Assisted Turn-Mill

LAT (Laser Assisted Turning) is an effective machining method for difficult to cut materials. Especially, because of the characteristics of a significant reduction in machining costs and flexibility in its machining, the applications of LAT have been largely extended to various machining fields. However, Studies on LAT are still staying at the beginning of research and represent a limitation in which a LAT process was applied to round members only. According to increases in customized production of special purpose parts, the researches on LAT for clover or polygon section members are necessary. In this paper, a LATM (laser assisted turn-mill) process was proposed to complement LAT.

Thermal Model of High-Speed Spindle Units

For the purpose to facilitate development of high-speed spindle units (SUs) running on rolling bearings, we have developed a beam element model, algorithms, and software for computer analysis of thermal characteristics of SUs. The thermal model incorporates a model of heat generation in rolling bearings, a model of heat transfer from bearings, and models for estimation of temperature and temperature deformations of SU elements. We have carried out experimental test and made quantitative evaluation of the effect of operation conditions on friction and thermal characteristics of the SUs of grinding and turning machines of typical structures. It is found out that the operation conditions make stronger effect on SU temperatures when rpm increases. A comparison between the results of analysis and experiment proves their good mutual correspondence and allows us to recommend application of the models and software developed for design and research of high-speed SUs running on rolling bearings.

Design of a Reduction Gear using Double-Enveloping Worm Gear

Worm gear sets may be either single- or double-enveloping. In a single-enveloping set, the worm wheel is cut into a concave surface, thus partially enclosing the worm when meshed. The double enveloping worm gear is similar to the single-enveloping gear; however, the worm envelopes the worm gear. Thus both are throated. The double-enveloping worm gear has more of the tooth surface in contact than the single-enveloping worm gear. The larger contact area increases the load-carrying capacity. For this reason, double-enveloping worm gearing is widely applied in heavy-duty machinery, for applications including construction and metallurgy. In this paper, we designed a compact reduction gear that is highly efficient using double-enveloping worm gears. We calculated the bearing load in the worm gearing to select the bearing and the housing surface area according to the recommended values from AGMA(American Gear Manufacturers Association). The finite element method was used to assess the structural integrity.

A Study on Shape Optimization of High-Speed Index Table with Hypoid Gear

In the recent field of Machining, with the improving efficiency of processing, the index table is a key unit according to the increase of parts in available processing when working with the three axes at the same time. As an essential product of MCT, the index tables effect an influence on product quality of machined parts. Therefore, it is necessary to design the shape of index table with stability, high stiffness, lightweight structure. In this study, the optimal shape of index table was proposed using by design of experiment. The maximum displacement and stress analysis were carried out by using FEM software. The optimized shape was verified by using the statistical software. The results of shape optimization were confirmed that both displacement and stress were reduced in comparison with initial model.

Effect of Surface Treatment on Fatigue Strength of SCM440H

Increased efficiency and improved performance associated with light-weight materials were investigated in this study. Numerous studies have investigated surface treatments to improve the fatigue strength of metals. Laser heat treatment is a promising method because the power and spot size can be easily controlled, allowing a small heat affected zone (HAZ). However, changes in the material properties can result; in particular, the material can become more brittle. In this study, a combination of laser heat treatment and vibration peening was proposed to increase fatigue strength without changing the material characteristics. SCM440H was investigated experimentally, and specimens were tested using a giga-cycle ultrasonic fatigue tester. The results show that the combination of these two processes significantly increased the fatigue strength and, furthermore, different fracture types were observed after a small and large number of cycles.

A Fundamental Study on the Prediction of Preheating Temperature of Silicon Nitride Ceramics by Using HPDL

Silicon nitride ceramic has been used in various engineering applications such as bearings, rollers, and exhaust valves for automobiles because of its corrosion resistance, high-temperature strength and low density. LAM (Laser assisted machining) has recently been considered as an alternative and effective process for machining ceramic materials. The laser heat sources in laser assisted milling processes are irregularly varied according to shapes of workpieces. Therefore, prediction and analysis of preheating temperature is difficult. In this study, the thermal analysis and experiment were performed to evaluate the surface temperature distribution of silicon nitride according to laser power. In addition, the preheating temperature was predicted by analyzing the results of the thermal analysis.