• Title/Summary/Keyword: FEM Forming

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Development of CAMPform2D Preprocessor for Forming Process U sing Convenient Input Method (편리한 입력방식의 단조공정해석을 위한 CAMPform 2D의 Preprocessor 개발)

  • 박성균;이상헌;이강수
    • Korean Journal of Computational Design and Engineering
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    • v.9 no.2
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    • pp.133-142
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    • 2004
  • CAMPfonn2D is a Finite Element Method (FEM) based process simulation system designed to analyze two dimensional (2D) flow of various metal forming processes. It enables designers to analyze metal forming processes on the computer rather than the shop floor using trial and error and provides vital information about material and thermal flow during the forming process to facilitate the design of products. CAMPfonn2D can be used by companies, research institutes and industrial applications to analyze forging, extrusion, drawing, heading, upsetting and many other metal forming processes. Also, process simulation using CAMPfonn2D can be instrumental in cost, quality and delivery improvements at leading companies. Today's competitive pressures require companies to take advantage of every tool for rapid manufacturing of well-designed product. So, the preprocessor of simulation program must be easy to use to speed-up design. In this paper, we introduce new version of Preprocessor and show how easy to use it. And, Preprocessor will prove itself to be easy and extremely effective.

Analysis of Superplastic Forming Process Design Using a Combined Stretch/Blow Process for Uniform Thickness Distribution (균일한 두께분포를 위한 신장/블로 공정을 이용한 초소성 성형 공정설계 해석)

  • Hong, S.S.;Lee, J.S.;Kin, Y.H.
    • Journal of the Korean Society for Precision Engineering
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    • v.11 no.1
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    • pp.129-137
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    • 1994
  • A rigid-viscoplastic finite element method has been used for modeling superplastic stretch/blow process design to improve thickness distribution. Punch velocity-time relationship of the stretch forming and pressure-time cycle of the blow forming for a given strain rate are calculated. A superplastic material is assumed to be isotropic and a plane-strain line element based on membrane approximation is employed for the formulation. The effects of the width, corner radius and height of the punch during stretch forming are examined for the final thickness distribution, and the process design to improve thickness distribution can be established.

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A Study on the Superplastic Sheet Forming by the FEM and Experiment (초소성 판재 성형을 위한 유한요소 해석 및 실험에 관한 연구)

  • Lee, Seung-Jun;Lee, Jung-Hwan;Lee, Young-Seon
    • Proceedings of the KSME Conference
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    • 2000.04a
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    • pp.866-872
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    • 2000
  • Superplastic forming processes by characteristic of low flow stress and high elongation have advantages to reducing on production cost and weight because of the product of complex form could be made in one part. However superplastically termed part has a characteristic of non-uniform thickness distribution along forming direction. Especially. since the thickness distribution affects on mechanical properties of product. the uniform thickness is very important. There are two solution procedure of implicit and explicit procedure to analyze the superplastic forming. In this study to analyze the thickness distribution two kinds of commercial programs of DEFORM and PAM-STAMP which implicit and explicit code are used respectly. The results from the two Programs were compared with eath other As a result implicit code were more suitable than explicit code for superplastic forming analysis.

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Forming Process Design of Fuel Injector Housing by Response Surface Method (반응표면분석법을 이용한 연료분사하우징의 성형공정설계)

  • Park K. H.;Yeo H. T.;Hur K. D.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2004.10a
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    • pp.311-314
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    • 2004
  • The housing of the fuel injector supports the rod, the niddle valve and the solenoid. Based on the procedure of process design, in this paper, the forming operation is designed by the rigid-plastic finite element method. The metal flow during the forming of the fuel injector housing is axisymmetric until the final forming process. The response surface method has been performed to reduce the under-fill and the maximum effective strain. From the results of RSM, the second order regression model of equation is calculated by the least square method and used to determine the optimal values of design variables by simultaneously considering the responses. It is noted that upper under-fill is affected by the design variables of the $2^{nd}$ forming process and lower under-fill is affected by the design variables of the 1st forming process.

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A Development of Wet-based Virtual Press (웹 기반의 가상 프레스 개발)

  • 정완진;장동영;이학림;최석우;나경환
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2002.05a
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    • pp.121-124
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    • 2002
  • This paper resents a virtual forming system to simulate deep drawing process for stress-strain information by utilizing virtual system designed using Virtual Reality Modeling Language (VRML) and computer aided analysis (CAE) tool. The CAE tool to calculate stress, strain, and deformation is designed using Finite Element Method. Stress distributions and deformation profiles as well as the operation of forming machine can be simulated and visualized in the web. The developed system consists of three modules, input module, virtual forming machine module, and output module. The input nodule was designed using HTML and ASP. The input data for FEM calculation is directed to the forming machine module for calculation. The results from the forming machine module can be visualized through output module as well as the forming process simulation.

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Evaluation of Forming Limits of Automotive Muti-phase Steel Sheets (자동차용 다상복합조직강판의 성형한계 평가)

  • Lee, S.Y.;Jeong, J.Y.;Park, S.H.;Kim, S.;Keum, Y.T.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2009.05a
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    • pp.195-198
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    • 2009
  • In this study, in order to get the forming limit of AHSS sheet in the negative minor strain region, the shapes of die corner and drawbead are redesigned by employing the Taguchi's design of experiment method and the FEM forming simulation. With the redesigned FLD tool, the forming limit tests of automotive multi-phase(Dual Phase and Complex Phase) steel sheets which induce the normal fractures on the blank are performed.

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Flexible Roll Forming Technology for Multi-Curved Sheet Metal Forming (다중곡률형상의 판재성형을 위한 가변롤성형 기술)

  • Yoon, J.S.;Son, S.E.;Song, W.J.;Kim, J.;Kang, B.S.
    • Transactions of Materials Processing
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    • v.22 no.5
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    • pp.243-249
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    • 2013
  • The multi-point forming (MPF) process for three-dimensional curved sheet metal has been developed as an alternative to the conventional die forming process since MPF allows the manufacturing of various shapes using one die set and reduce the cost of production. However, the MPF process cannot provide high quality products yet due to defects occurring in the sheet such as dimples and wrinkles. It can also lead to economic loss because of long tool setup time and additional machining required outside of the sheet formed area. In this study, a new sheet metal forming method, called flexible roll forming (FRF), is proposed to solve the problems of existing processes for three-dimensional curved sheet metal. This progressive process utilizes adjusting rods, as well as upper and lower flexible rollers as forming tools. In contrast with the existing processes, FRF can reduce the additional production costs because of the possible blank size for the part longitudinal direction, which is unrestricted. In this research, methods and procedures of the flexible roll forming technology are described. Numerical forming simulations of representative three-dimensional curved sheet products are also carried out to demonstrate the feasibility of this technology.

Design of Roll-to-Roll Forming Process for Micro Pattern on the Thin Sheet Metal by Finite Element Analysis (유한요소해석을 이용한 마이크로 박판 미세 패턴 롤-롤 성형공정 설계)

  • Cha, S.H.;Shin, M.S.;Lee, H.J.;Kim, J.B.
    • Transactions of Materials Processing
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    • v.19 no.3
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    • pp.167-172
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    • 2010
  • Roll-to-roll forming process is one of important metal processing technology because the process is simple and economical. These days, with these merits, roll-to-roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate. However, it is difficult to apply to the forming of micro scale or sub-micro scale pattern. In this study, the roll forming processing for the micro scale is designed and analyzed. The forming of micro pattern for small electric device such as LCD panel by incremental roll forming process is analyzed. Firstly, the optimum analysis conditions are found by several analyses. And then, formability is analyzed for various protrusion shapes at various forming temperatures. The formability is evaluated in terms of filling ratio and damage value. The filling ratio is defined from the tool geometry and critical damage is determined from the analysis of uniaxial tensile test. Finally, optimum forming conditions that guarantee the successful forming are found.

Experimental Study on the Development of a Forming Process for Manufacturing Doubly-curved Sheet Metal (이중 곡률을 갖는 판재의 성형 공정의 개발에 대한 실험적 연구)

  • 양동열
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1999.03b
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    • pp.18-21
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    • 1999
  • In this study in order to make doubly-curved sheet metal effectively a sheet metal forming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation to thickness The developed process is an unconstrained forming process with no holder. For this study the experimental equipment is set up with the punch-set which consists of two pairs of lower support-punches and one upper center-punch. In the experiments using aluminum sheet it is found that the curvature of the formed sheet metal is determined by controlling the distance between supporting punches in pairs and the forming depth of the center-punch. and the edge-forming method is proposed for forming the sheet metal into the balanced shape. The equation using process variables such as the distance between supporting punches in pairs and the forming depth of the center-punch is proposed for the prediction of the radii of curvatures of the formed shape and it is corrected by the experimental results and the FEM simulation results about whether springback takes place. It is found that according o the simulation there is a certain set of the distance between a pair of supporting punches and the forming depth of the center-punch which causes a little springback. It is thus shown that the radii of curvatures of the formed sheet metal can be predicated by the corrected equation unless significant springback occurs.

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A Study on the Multi-row Progressive Die for Thin Sheet Metal Forming by Computer Simulation

  • Sim, Sung-Bo;Kim, Chung-Hwan
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.7 no.3
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    • pp.75-80
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    • 2008
  • The progressive die performs a work of sheet metal processes with a piercing, notching, embossing, bending, drawing, cut-off etc. in many kinds of pressing. Now a days, these processes have been evaluated as a advanced tooling method to increase the productivity and high quality assurance. The first step analyzing of die design is production part review, then the arrangement drawing of product design and strip process layout design should be done as a next steps with a FEM simulation for its problem solution. After upper procedure were peformed, it was started to make the die, then tryout and its revision of the die and product quality, safety, productivity etc. were done continually. For the all of these process, we mobilized the theory and practice of sheet metal forming, die structure, the function and activity of die components, and the others of die machining, die material, heat treatment and know‐how so on. In this study the features of representative are production part analyzing through the FEM simulation of bending area with a considering spring back problem by DEFORM.

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