• Transactions of Materials Processing
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• v.25 no.5
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• pp.319-324
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• 2016

Recently, the roll forming process is one of the most widely used processes for manufacturing automotive part. In this study, flower patterns of roll forming process were designed to manufacture an ultra high strength bumper beam using the finite element analysis. Three types of flower patterns such as the basic type, the rotation type and the split type were designed based on the constant arc length forming method using the design software, UBECO Profil. Finite element analysis was performed to evaluate the suitability of designed flower patterns in terms of the longitudinal strain and the bow defect. The analytical results show that the split type represents more uniform longitudinal strain distributions and a good dimensional accuracy than other types of flower patterns.

• Transactions of Materials Processing
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• v.31 no.4
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• pp.194-199
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• 2022

In finite element method (FEM) simulations, constitutive models are widely used and developed to represent a wide range of true stress-strain curves using a small number of modeling parameters. Nevertheless, many studies has been conducted to find a suitable constitutive model and optimal modeling parameters to represent experimentally obtained true stress-strain curves. Therefore, in this study, a new constitutive modeling approach using the combined Swift and Voce model is suggested, and confirmed through comparisons of the experimental results with the FEM simulation results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.292-296
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• 2008

A new method of evaluating critical damage values of commercial materials is presented in this paper. The method is based on the previous study of the methodology [1] of acquisition of true stress-strain curves or flow stress curves over large strain from the tensile test in which the flow stress is described by the Hollomon law-like form, that is, by the strain dependent strength coefficient and the strain hardening exponent. The strain hardening exponent is calculated from the true strain at the necking point to meet the Considere condition. The strength coefficient is assumed to be constant before necking and represented by a piecewise linear function of strain after necking. With the predicted flow stress, a tensile test is simulated by a rigid-plastic finite element method with higher accuracy of less than 0.5% error between experiments and predictions. The instant when the fracture begins and thus the critical damage is obtained is determined by observing the stress variation at the necked region. It is assumed that the fracture due to damage begins when the pattern of stress around the necked region changes radically. The method is applied to evaluate the critical damage of a low carbon steel.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.270-273
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• 2003

The strain measurement of the panel in the sheet metal forming is essential work which provides experimental data needed to die design, process design, and product inspection. To measure efficiently the complex geometry strain, the 3-dimensional automative strain measurement system, which has high accuracy in theory, but has some 3∼5% errors in practice, is often used. The object of this study is to develop the error compensation technology to eliminate the strain, errors resulted when formed panels are measured using an automated strain measurement system. To achieve the study object, the position error calibration method correcting coordinates of the grid node recognized by a camera using error functions is suggested. Then the position errors were found by calculating the difference in the position of the cube node between real coordinates and measured coordinates in toms of node coordinates and the error calibration equations were derived by regressing the position errors. In order to show the validation of the suggested position error calibration method, finite element analysis and current calibration method was performed for the initial-blankformed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.309-312
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• 2001

FEM simulating system of the cross-rolling texture formation offers a systematic and efficient way of exploring the relationship between the process variables and the state of plastic anisotropy of sheet product. Cross-rolled sheets possess higher average plastic strain ratios and lower planer anisotropy than those of the straight-rolled sheets. The employed model is a finite-element polycrystal model which each element used in FEM is assumed to be a crystal having different orientation by Takahashi. Texture development, deformation textures due to cross-rolling are predicted for face-centered cubic sheet metal. Crystal orientations are assigned on the basis of the pole figures obtained by X-ray diffraction. Development of anisotropy during cross rolling of an fcc sheet material is predicted theoretically with respected to flow stress and R-value in tensile test.

• Transactions of Materials Processing
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• v.21 no.7
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• pp.447-452
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• 2012

This paper is concerned with forming of Al-Zn-Mg-Sc aluminum alloy bolts, focusing on the effects of heat treatment and age-hardening on the formability and ductile damage evolution. Both experimental and finite element studies were performed. From the experiments, it is observed that the heat treatment or the normalization of Al-Zn-Mg-Sc aluminum alloy increases its formability dramatically resulting in successful bolt forming, while the effects of age-hardening at room temperature on the stress-strain relationship and formability are not very critical. Deformation characteristics such as distribution of effective stress and strain, material flow, and ductile damage evolution during bolt forming are examined using a commercial finite element package, Deform-2D. It should be noted that the extrusion load predicted by the finite element method matches well the experiment results. The finite element predictions on the deformation characteristics support the experimental observations such as fracture of bolt head flange, material flow, and distribution of hardness.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.226-228
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• 2007

During asymmetrical cold rolling in AA 5052 sheet a reduction per a rolling pass was varied to investigate the effect of the ratio of the contact length between the roll and sample ($l_c$) to the sheet thickness (d) on the formation of shear textures. In order to intensify the shear deformation during asymmetrical rolling, AA 5052 sheet was asymmetrically cold rolled without lubrication by using different roll velocities of upper and lower rolls. Asymmetrical rolling with $l_c$/d=1.8 led to the formation of texture gradients throughout the sheet thickness in which the outer thickness layers depicted shear textures and the center thickness layers displayed a rolling texture. Asymmetrical rolling with $l_c$/d=3.1 gave rise to the formation of shear textures in the whole through-thickness layer. The strain states associated with asymmetrical rolling were investigated by the finite element method (FEM) simulation. FEM results indicated that the evolution of deformation texture in a thickness layer is strongly governed by integrated values of strain rates and along the streamline in the roll gap.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.95-98
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• 2008

In the present work, cross-roil rolling was rallied out using a rolling mill in which the roll axes are tilted by $5^{\circ},\;7.5^{\circ},\;10^{\circ}$ towards the transverse direction of the roiled sample. The evolution of strain states during cross-roll rolling was investigated by three-dimensional finite element method (FEM) simulation. Parallel to cross-roll rolling, normal-rolling using a conventional rolling mill was also carried out in the same rolling condition for clarifying the effect of cross-roll rolling. It turned out that three shear rate components were all introduced to the rolled sample by the cross-roll rolling process, while only one shear rate component operated during normal-rolling.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.47-52
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• 2004

Springback comes from the release of residual stress after forming. The control of phenomenon is especially important in the sheet metal forming since there are no other practical methods available to correct the dimensional inaccuracy from springback. Therefore the accurate predication before the die machining has been a long goal in the Held of sheet metal forming. The aim of the present study is to enhance the prediction capability of finite element(FE) analysis for the springback phenomenon. For this purpose FE analysis for V-bending has been carried out with the commercial programs, LS-DYNA. The FE analysis results have been validated through the comparison of experimental. The experimental results measured directly by the strain gauge have given the confidence to FEA.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.460-462
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• 2005

Asymmetrical rolling was performed with different working roll speeds of upper and lower rolls. In order to promote the shear deformation during asymmetrical rolling, various deformation parameters of initial sheet thickness, rolling reduction, roll speed ratio and roll radius are considered. The evolution of texture during asymmetrical rolling was shown by the calculation of orientation distribution function (ODF). The effect of deformation parameters on shea. deformation were investigated by simulations with the finite element method (FEM). Asymmetrical rolling gave rise to the development of pronounced strain gradients throughout the thickness layers which resulted in the formation of strong texture gradients in the sheet.