• Title/Summary/Keyword: Forming Parameters

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Tendency Analysis of Shape Error According to Forming Parameter in Flexible Stretch Forming Process Using Finite Element Method (유한요소법을 이용한 가변스트레치공정 성형변수에 따른 성형오차 경향분석)

  • Seo, Y.H.;Heo, S.C.;Song, W.J.;Kim, J.;Kang, B.S.
    • Transactions of Materials Processing
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    • v.19 no.8
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    • pp.486-493
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    • 2010
  • A shape error of the sheet metal product made by a flexible stretch forming process is occurred by a various forming parameters. A die used in the flexible stretch forming is composed of a punch array to obtain the various objective surfaces using only one die. But gaps between the punches induce the shape error and the defect such as a scratch. Forming parameters of the punch size and the elastic pad to prevent the surface defect must be considered in the flexible die design process. In this study, tendency analysis of shape error according to the forming parameters in the flexible stretch process is conducted using a finite element method. Three forming parameters, which are the punch size, the objective curvature radius and the elastic pad thickness, are considered. Finite element modeling using the punch height calculation algorithm and the evaluation method of the shape error, which is a representative value for the formability of formed surface, are proposed. Consequently, the shape error is in proportion to the punch size and is out of proportion to the objective curvature radius and the elastic pad thickness.

Characterization of Mechanical Properties of Boron Steel Sheet in Hot Bending Process with Various Parameters

  • Yang, Li;Kang, Chung-Gil
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2009.10a
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    • pp.375-378
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    • 2009
  • Hot press forming is a new forming process which also names as hot stamping. It can greatly enhance the formability of forming parts. This paper researches the formability of boron steel sheet in hot bending process which is a kind of hot press forming. In the text, the influence of hot press forming processing parameters, such as the heating temperature, blank holding force, punch speed and punch and die radius, on the mechanics properties and microstructure of the hot bending parts was analyzed by tension test and the metallographic observation on the parts with various processing parameters. The relationship between blank holding force and punch load was also presented.

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Study on Design Parameters that Affect the Forming Force of the Magnetic Pulse Forming Device (자기 펄스 성형장치의 성형력에 영향을 미치는 설계 파라미터에 관한 연구)

  • Lee, Man Gi;Yi, Hwa Cho;Kim, Jin Ho
    • Journal of the Korean Magnetics Society
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    • v.25 no.3
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    • pp.79-82
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    • 2015
  • The design parameter study about the magnetic pulse forming is performed using finite element analysis with MAXWELL. The first case of design parameters is about the initial charging voltage and the capacitance and the second case of design parameters are about the winding turns and the spacing of electromagnetic coil. The 3D finite element model of electromagnetic forming system is created and the magnetic force is calculated. The effects of design parameters on the magnetic forming force are investigated.

Optimum Design of the Process Parameter in Sheet Metal Forming with Design Sensitivity Analysis using the Direct Differentiation Approach (II) -Optimum Process Design- (직접미분 설계민감도 해석을 이용한 박판금속성형 공정변수 최적화 (II) -공정 변수 최적화-)

  • Kim, Se-Ho;Huh, Hoon
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.26 no.11
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    • pp.2262-2269
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    • 2002
  • Process optimization is carried out to determine process parameters which satisfy the given design requirement and constraint conditions in sheet metal forming processes. Sensitivity -based-approach is utilized for the optimum searching of process parameters in sheet metal forming precesses. The scheme incorporates an elasto-plastic finite element method with shell elements . Sensitivities of state variables are calculated from the direct differentiation of the governing equation for the finite element analysis. The algorithm developed is applied to design of the variablc blank holding force in deep drawing processes. Results show that determination of process parameters is well performed to control the major strain for preventing fracture by tearing or to decrease the amount of springback for improving the shape accuracy. Results demonstrate that design of process parameters with the present approach is applicable to real sheet metal forming processes.

Manufacture of Doubly Curved Sheet Metals Using the Incremental Roll Forming Process and Prediction of Formed Shapes for Precision Forming (점진적 롤 성형공정을 이용한 이중곡률의 금속판재 제작 및 정밀성형을 위한 형상 예측)

  • 윤석준;양동열
    • Journal of the Korean Society for Precision Engineering
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    • v.21 no.9
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    • pp.95-102
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    • 2004
  • A flexible incremental roll forming process has been developed by adopting the advantages of the incremental forming process and the roll forming process: i.e., inherent flexibility of the incremental forming process and continuous bending deformation of the roll forming process. It has an adjustable roll set as a forming tool composed of one upper center roll and two pairs of lower support rolls, which plays a key role during forming process. Through the experiments based on the various combinations of process parameters, it is shown that the incremental roll forming process is so effective as to manufacture various doubly curved sheet metals including concave-convex combination shapes in which there exists a line of inflection. The proposed relationship of the experimental parameters and the radius of curvature of the formed sheet boundary is found to be useful in prediction and control of the final shape.

Optimization of Incremental Sheet Forming Al5052 Using Response Surface Method (반응표면법을 이용한 Al5052 판재의 점진성형 최적화 연구)

  • Oh, S.H.;Xiao, X.;Kim, Y.S.
    • Transactions of Materials Processing
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    • v.30 no.1
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    • pp.27-34
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    • 2021
  • In this study, response surface method (RSM) was used in modeling and multi-objective optimization of the parameters of AA5052-H32 in incremental sheet forming (ISF). The goals of optimization were the maximum forming angle, minimum thickness reduction, and minimum surface roughness, with varying values in response to changes in production process parameters, such as tool diameter, tool spindle speed, step depth, and tool feed rate. A Box-Behnken experimental design (BBD) was used to develop an RSM model for modeling the variations in the forming angle, thickness reduction, and surface roughness in response to variations in process parameters. Subsequently, the RSM model was used as the fitness function for multi-objective optimization of the ISF process based on experimental design. The results showed that RSM can be effectively used to control the forming angle, thickness reduction, and surface roughness.

Effect of Process Parameters in Electromagnetic Forming Apparatus on Forming Load by FEM (유한요소해석을 통한 전자기 성형장비 공정변수의 성형력에 미치는 영향)

  • Noh, Hak Gon;Park, Hyeong Gyu;Song, Woo Jin;Kang, Beom Soo;Kim, Jeong
    • Journal of the Korean Society for Precision Engineering
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    • v.30 no.7
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    • pp.733-740
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    • 2013
  • The high-velocity electromagnetic forming (EMF) process is based on the Lorentz force and the energy of the magnetic field. The advantages of EMF include improved formability, wrinkle reduction, and non-contact forming. In this study, numerical simulations were conducted to determine the practical parameters for the EMF process. A 2-D axis-symmetric electromagnetic model was used, based on a spiral-type forming coil. In the numerical simulation, an RLC circuit was coupled to the spiral coil to measure various design parameters, such as the system input current and the electromagnetic force. The simulation results show that even though the input peak current levels were at the same level in each case, the forming condition varied due to differences in the frequency of the input current. Thus, the electromagnetic forming force was affected by the input current frequency, which in turn, determined the magnitude of the current density and the magnetic flux density.

Effective Process Parameters on Shape Dimensional Accuracy in Incremental Sheet Metal Forming (점진성형에서 형상 정밀도에 영향을 미치는 공정 변수)

  • Kang, Jae-Gwan;Jung, Jong-Yun
    • Journal of Korean Society of Industrial and Systems Engineering
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    • v.38 no.4
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    • pp.177-183
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    • 2015
  • Incremental sheet metal forming is a manufacturing process to produce thin parts using sheet metals by a series of small incremental deformation. The process rarely needs dedicated dies and molds, thus, preparation time for the process is relatively short as to be compared to conventional metal forming. Spring back in sheet metal working is very common, which causes critical errors in dimensions. Incremental sheet metal forming is not fully investigated yet. Hence, incremental sheet metal forming frequently produces inaccurate parts. This paper proposes a method to minimize dimensional errors to improve shape accuracy of products manufactured by incremental forming. This study conducts experiments using an exclusive incremental forming machine and the material for these experiments are sheets of aluminum AL1015. This research defines a process parameter and selects a few factors for the experiments. The parameters employed in this paper are tool feed rate, tool diameter, step depth, material thickness, forming method, dies applied, and tool path method. In addition, their levels for each factor are determined. The plan of the experiments is designed using orthogonal array $L_8$ ($2^7$) which requires minimum number of experiments. Based on the measurements, dimensional errors are collected both on the tool contacted surfaces and on the non-contacted surfaces. The distances between the formed surfaces and the CAD models are scanned and recorded using a commercial software product. These collected data are statistically analyzed and ANOVAs (analysis of variances) are drawn up. From the ANOVAs, this paper concludes that the process parameters of tool diameter, forming depth, and forming method are the significant factors to reduce the errors on the tool contacted surface. On the other hand, the experimental factors of forming method and dies applied are the significant factors on the non-contacted surface. However, the negative forming method always produces better accuracy than the positive forming method.

Effective Process Parameters on Surface Roughness in Incremental Sheet Metal Forming (점진성형에서 표면거칠기에 영향을 미치는 공정 변수)

  • Lee, Sang-Yoon;Lee, Kyeong-Bu;Kang, Jae-Gwan
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.13 no.6
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    • pp.66-72
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    • 2014
  • Incremental forming is a relatively novel sheet forming process, in which parts can be formed without the use of dedicated dies. In this paper, the influence of the process parameters (tool diameter, step size, feed rate, existence of a die, forming methods, and kinds of tool path) on surface roughness in the case in which parts are processed by incremental forming was discussed. Al 1050 material is used in the experiments. A table of orthogonal arrays is used to design the experiments and the ANOVA method is employed to statistically analyze the results. The obtained results show that the process parameters of tool diameter, step size, and the existence of a die have a significant effect on the surface roughness, whereas the feed rate, forming methods and kinds of tool path are insignificant.

A Concept of Self-Optimizing Forming System (자율 최적 성형 공정 시스템 개발)

  • Park, Hong-Seok;Hoang, Van-Vinh;Song, Jun-Yeob;Kim, Dong-Hoon;Le, Ngoc-Tran
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.22 no.2
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    • pp.292-297
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    • 2013
  • Nowadays, a strategy of the self-optimizing machining process is an imperative approach to improve the product quality and increase productivity of manufacturing systems. This paper presents a concept of self-optimizing forming system that allows the forming system automatically to adjust the forming parameters online for guarantee the product quality and avoiding the machine stop. An intelligent monitoring system that has the functions of observation, evaluation and diagnostic is developed to evaluate the pully quality during forming process. Any abnormal variation of forming machining parameters could be detected and adjusted by an intelligent control system aiming to maintain the machining stability and the desired product quality. This approach is being practiced on the pully forming machine for evaluating the efficiency of the proposed strategy.