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In order to join two ultra-high strength steel sheets with low ductility for automobile parts, a joining process by hemming with a pre-bent inner sheet was developed. In this joining, the pre-bent inner sheet instead of the conventional flat inner sheet was used to relax the deformation concentration of the outer sheet. Although 780 MPa steel sheets were joined without the pre-bent inner sheet, a fracture in the outer sheet occurred in joining the 980 MPa sheets due to the low ductility of the sheets. The 980 MPa and 1180 MPa sheets were successfully joined by hemming with the pre-bent inner sheet. In this process, the deformation of the upper sheet was relaxed by contacting with the inner sheet, and then the strain on the outer surface reduced. Although softening around a weld nugget occurred by heating in the conventional welded joint, work-hardening occurred in the hemmed joint. The joint strength was investigated and then the peel strength of the hemmed sheets was about a half of the welded one. It was found that the hemming process with the pre-bent inner sheet was effective for joining ultra-high strength steel sheets with low ductility.

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We have developed a plasticating simulation program for injection molding machines based on Chungs melting model. We compared the simulation results with the results of experiments which employed a visualization cylinder. The visualization cylinder has sight glass windows through which we can observe the melting phenomena in the cylinder. We established the temperature of resin in the cylinder by using infrared thermograph. The temperature of resin obtained by the simulation was close to experimental one. On the other hand, the solid-bed ratio deviated from the experiment results especially in the compression zone when the screw rotation speed was low. This suggests that the calculation of heat in the melting process should be improved.