• 한국자동차공학회논문집
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• 제21권5호
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• pp.82-86
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• 2013

The automotive weather strip has the functions isolating of dust, water, noise and vibration from outside. The core of weather strip is made of steel with stiffness. By using the wire formed as the core of weather strip, weight can be reduced as much as 35% by comparing with existing steel core. For this reason, forming wire is necessary to keep the zigzag shape as it is. The deformation which is occurred during forming process can be predicted and it can be used in case of manufacturing dies through CAE. In this paper, rolling process conditions are deduced and the springback amount is predicted after rolling process by using the simulation. The springback amount of product is measured by using optical microscope, and measurement result is compared with the simulation result of springback as the same condition. The suitable gap between dies to compensate springback after rolling process is predicted through simulation and it is used for manufacturing dies.

• 한국기계기술학회지
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• 제13권1호
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• pp.105-112
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• 2011

Increasing needs for light weight and high safety in modern automobiles induced the wide application of high strength steels in automotive body structures- The main difficulty in the forming of sheet metal parts with high strength steel is the large amount of springback including sidewall curl and twist in channel shaped member parts- Among these shape defects, twist occurs frequently and requires numerous reworks on the dies to compensate the shape deviation- But until now, it seems to be no effective method to reduce the twist in the forming processes- In this study, a new forming process to reduce the twist deformation during the forming of automotive structural member was suggested- This method consists of forming and restriking of embosses on the sidewall around the stretch flanging area of the part- and was applied in the forming process design of an automotive front side inner member with high strength steel- To evaluate the effectiveness of the method, springback analysis using $Pamstampa^{tm}$ was done- Through the analysis results, the suggested method was proven to be effective in twist reduction of channel shaped parts with stretch flanging area.

• 소성∙가공
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• 제30권6호
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• pp.275-283
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• 2021

A parametric study was conducted on the effects of five fundamental design parameters on springback, including die clearance, step height, step width, punch radius, and taper relief in an L-bending process, controlled by the compression force. The experiment was also conducted to verify the usefulness of the parametric study procedure for process design, as well as the finite element predictions. The elastoplastic finite element method was utilized. The L-bending process of the york product, which is a key part of the breaker mechanism, was employed. The deformation of the material was assumed to be due to plane strain. Five samples of each design parameter were selected based on experiences in terms of process design. The finite element predictions were analyzed in detail to show a shortcut towards the process design improvement which can replace the traditional process design procedure relying on trial-and-errors. The improved process design was verified to meet all the requirements and the predictions and experiments were in good agreement.

• Design & Manufacturing
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• 제15권2호
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• pp.63-69
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• 2021

Springback is an essential task to be solved in order to make high-precision products in sheet metal forming. In this study, materials with four different elastic regions were used. For the forming analysis, the change of springback caused by the frictional force generated in the flange part during hat shape forming was considered by using the AutoForm analysis program. Factors affecting frictional force were blank holder force, friction coefficient, bead R and bead height. As a result of the forming analysis, the springback increases as the material with a larger elastic region increases. In addition, as the frictional force of the flange part increased, the tensile force in the forming direction increased and the springback decreased. In particular, the blank holder force and friction coefficient had a great effect on springback in mild materials (DC04, Al6016), and the bead effectively affects all materials. Through this study, it was considered that the springback decreased as the material with a smaller elastic region and the tensile force in the forming direction increased.

• 한국지반공학회지:지반
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• 제13권3호
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• pp.33-52
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• 1997

비선형 3차원 유한요소 해석법을 이용하여 타이백으로 억지된 토류벽의 거동을 분석하여 설계시에 고려되는 중요 파라미터의 영향을 조사하였다. 제안된 유한요소기법에서 엄지말뚝과 텐던 정착길이는 빔요소로, 토류판은 쉘요소로, 텐던 비정착길이는 스프링 요소로 모델링하였다. 사용된 흙의 거동모델은 사질토의 비선형 거동 특성과 응력이력을 고려할 수 있는 기존의 Hyperbolic 모델을 수정하여 사용하였으며 벽체 전면에서의 굴착, 타이백 설치, 타이조임 그리고 재굴착 등의 모든 축조과정을 단계별로 해석할 수 있는 시뮬레이션 기법을 제안하였다. 여러 가지 주요 설계인자를 변화시키며 파라메트릭 해석을 수행하였고 이 결과 앵커의 위치, 앵커의 비정착 길이, 앵커 조임 하중의 크기와 엄지말뚝의 근입긴이등의 영향을 밝혀낼 수 있었다. 이 해석 결과를 토대로 새로운 설계지침을 제안하였다.

• 소성∙가공
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• 제16권7호
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• pp.509-515
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• 2007

As the springback of sheet metal during unloading may cause deviation from a desired shape, accurate prediction of springback is essential for the design of sheet stamping operations. When considering the case of a sheet metal being bent to radius $\rho$ that is such that the maximum stress induced exceed the elastic limit of the material, plastic strain in the outer surface will occur and the material will take a permanent set: but since, on removing the bending moment, the recovery of the material is not uniform across the thickness, springback will occur and the radius $\rho$ will not be maintained. Furthermore, when a tensile load being applied to each end of specimen, the tensile stress due to bending is increased and the compressive stress is decreased or cancelled and eventually the whole specimen may be in varying degree of tension. On the removal of the applied load the specimen loses its elastic strain by contracting around the contour of the block, the radius $\rho$ will be determined by the residual differential strain. Therefore in this study the springback is analytically estimated by the residual differential strains between upper and lower surfaces of greatest radius after elastic recovery, and a springback model based on the bending moment is also analytically derived for comparison purpose.

• 대한기계학회논문집A
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• 제37권10호
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• pp.1239-1249
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• 2013

본 연구에서는 zircaloy-4 판재에 대해 바우싱거 효과를 고려한 경화거동 예측모델을 구축했다. 금속소재 가공에서 인장 후 압축 시 항복응력이 감소한다. 이에 스프링백 해석 시 바우싱거 효과를 반드시 고려해야 한다. Simple shear 시험에서 적정 시편크기 및 적정 조임토크에 대한 결정법을 제시했다. 5 가지 재료에 대한 simple shear 시험을 통해 응력-변형률 곡선을 구했다. 또한 유한요소해석을 활용해 simple shear 하중-변위 곡선으로부터 유효응력-변형률 곡선으로 변환과정을 소개했다. 등방/운동성 경화 조합모델을 활용해 simple shear 순/역방향 시험을 모사했다. 이때 각 경화계수에 따른 하중-변위 곡선 변화를 관찰하고, zircaloy-4에 대한 경화계수를 결정했다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.493-496
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• 2008

The residual stress generated in the boron steel blank formed via hot press forming process was predicted by JMatPro, a material property modeler, and Abaqus. The numerical predictions were compared by the experimental measurements obtained by the instrumented indentation. Both the predicted and measured principal stresses monitored at the outer surface of central bending position were qualitatively in good agreement. It was concluded that the residual stresses generated from hot forming process is not negligible as it has been generally assumed, although the spring back deformation is quite small. This should be specially considered from the part design stage since the tensile nature of the residual stress exhibited on the surface may lead to the stress corrosion cracking.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.311-315
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• 2008

Currently, in automobile industry. the efforts to reduce the manufacturing cost by changing the process of manufacturing are continually performed. In this paper, we proposed a new manufacturing process, the roll bending of a ring plate of automotive fuel tank instead of conventional press blanking process to reduce material loss and manufacturing cost. Finite element analysis was used to optimize the roll bending process to assure rectangular cross-section of the ring plate. Also, spring-back analysis after the roll bending was performed and dimension of the bending die considering spring-back was analyzed. Finally, we verified a possibility for realization of the proposed method shape with prototypes.

• 한국산학기술학회논문지
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• 제11권11호
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• pp.4080-4086
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• 2010

본 연구에서는 대형 차체 판넬과 같은 유연성이 큰 판넬의 3차원 형상을 스캐닝 하기 위한 고정구를 개발하였다. 유연 판넬에 대한 N-2-1 설계원리에 따라 자중의 영향이 최소화되는 지지점들을 유한요소 해석을 통하여 선정함으로써 hood outer 판넬의 고정구를 설계하고, Alufix 시스템을 이용하여 스캐닝 고정구를 제작하였다. 제작된 고정구를 이용하여 레이저 스캐닝을 수행하여 성공적으로 스프링 백을 측정함으로써, 본 연구에서 제안된 고정구 제작 방안의 유용성을 확인하였다.