• 오토저널
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• 제12권6호
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• pp.48-59
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• 1990

A finite element program was developed using line elements for simulating the stretch/draw forming operation of an arbitrarily-shaped plane-strain section. An implicit, incremental, updated Lagrangian formulation is employed, introducing a minimum plastic work path assumption for each time step. Geometric and material nonlinearities are also considered within each time step. The finite element equation is based on the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshes without depending on the explicit spatial derivatives of tool surfaces. The membrane approximation is adopted under the plane stress assumption. The sheet material is assumed to obey a rigid-viscoplastic constitutive law. The developed program was tested in the die-tryout of typical automotive inner panels. In order to determine a single friction coefficient and boundary length, FEM results and measurements of thinning for a stretched section of final die were compared. After finding analysis parameters, the sheet forming operations of original and final die designs were simulated. Excellent agreement between measured and computed thickness strains was obtained and the developed program was able to identify die designs which were rejected during die tryout.

• Structural Engineering and Mechanics
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• 제35권6호
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• pp.699-715
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• 2010

This paper investigates the structural responses of axially restrained steel beams under fire conditions by a nonlinear finite element method. The axial restraint is represented by a linear elastic spring. Different parameters which include beam slenderness ratio, external load level and axial restraint ratio are investigated. The process of forming a mid-span plastic hinge at the mid-span under a rising temperature is studied. In line with forming a fully plastic hinge at mid-span, the response of a restrained beam under rising temperature can be divided into three stages, viz. no plastic hinge, hinge forming and rotating, and catenary action stage. During catenary action stage, the axial restraint pulls the heated beam and prevents it from failing. This study introduces definitions of beam limiting temperature $T_{lim}$, catenary temperature $T_{ctn}$ and warning time $t_{wn}$. Influences of slenderness ratio, load level and axial restraint ratio on $T_{lim}$, $T_{ctn}$ and $t_{wn}$ are examined.

• 소성∙가공
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• 제3권4호
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• pp.440-453
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• 1994

The multi-stage deep-drawing processes including normal-drawing, reverse-drawing, and re-drawing are analyzed by use of the rigid-plastic finite element method. Computational results on the punch/die loads and thickness distributions were compared with the experiments of the current drawing processes. Deep-drawing processes of the redesigned shell to improve the specific strength and stiffness were simulated with the numerical method developed. With varying several process parameters such as blank size, corner radii of tools, and clearances, the simulation results showed the improvements in reducing the forming loads. Also forming defects were found during simulation and appropriate blank size could be verified.

• 소성∙가공
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• 제19권2호
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• pp.113-119
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• 2010

Hydroforming is the technology that utilizes hydraulic pressure to form tube or sheet materials into desired shapes inside die cavities. Tube hydroforming provides a number of advantages over the conventional stamping process, including fewer secondary operations, weight reduction, assembly simplification, adaptability to forming of complex structural components and improved structural strength. In many case, hydroformed parts have to be structurally joined at some point. Therefore it is useful if the hydroformed automotive parts can be given a localized attachment flange. In this study for the numerical process design FE analysis was performed with DYNAFORM 5.5. Die parting angle and circumferential expansion ratio was optimized. With optimized condition, bulge and hydroforming experiments to form flange were performed. Forming characteristic at various pressure conditions was analyzed and optimized internal pressure condition was evaluated. The results show that flanged parts can be successfully produced by tube hydroforming process.

• 한국정밀공학회지
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• 제18권1호
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• pp.154-161
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• 2001

A UBET analysis has been carried out to predict the forming load and the extruded length of forward and backward extrusion of hexagonal and trochoidal wrench colts. For the upper bound load and the average length of the extruded billets are determined by minimizing the total energy consumption rate which is a function of unknown velocities and parameters at each element. Experiments are carried out with antimony-lead billets at room temperature using hexagonal and trochoidal shaped punches. The theoretical predictions of the forming load and the extruded length are in good agreement with the experimetal results.

• 한국자동차공학회논문집
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• 제16권1호
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• pp.86-92
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• 2008

Recently, the use of tubes in the manufacturing of the automobile parts has increased and therefore many automotive manufactures have tried to use hydro-forming technology. The hydro-forming technology may cause many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower spring-back, improved strength and durability and design flexibility. In this study, the whole process of front engine cradle (or front sub-frame) parts development by tube hydro-forming using steel material having tensile strength of 440MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydro-formability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape on automotive sub-frame by hydro-forming process were carefully investigated. Overall possibility of hydro-formable sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydro-forming. At the die design stage, all the components of prototyping tools are designed and interference with press is examined from the point of geometry and thinning.

• 소성∙가공
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• 제20권4호
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• pp.316-323
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• 2011

The hot curvature-forming of large aluminum thick plate using a grid-typed hybrid die is a process for the production of a spherical LNG tank. Many variables such as the initial die surface quality, grid size, grid thickness, size of blank plate and cooling line design, control the success of the process. In addition, the plate used in this process is generally larger than $10{\times}10m$ in size. Thus, it is very difficult to predict the surface characteristics of the plate during forming and to measure the different parameters due to the high cost of the experiments. In order to optimize the process design for the grid-type die, the development of an analytical method to predict the surface characteristics of the final product in hot curvature-forming is needed. This paper described the development of the method and procedures for FE simulations of the hot curvature-forming process, including hot forming, air flow, cooling, and thermal deformation analyses. An experiment for a small scale model of the process was conducted to check the validity of the numerical method. The results showed that the curvature of the plate in the analysis agrees well with that of the experiment within 0.037 and 0.016% tolerance margins for its side and corner, respectively.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 2004년도 ICCAS
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• pp.301-306
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• 2004

In this study, Dual servo mechanism with VCM(Voice Coil Motor) and PZT is designed for a high precision force and position control. We designed the VCM actuator and dual servo mechanism with leaf spring. VCM actuators, with their high linearity, simple structure, low weight, and high efficiency, are increasingly being used in micro-positioning applications. There are many kinds of VCM with a structure. VCM actuators are divided into two types by moving parts. One is moving magnet type and the other moving coil type. We described the properties of these two types of VCM. Design parameters of VCM are defined through the FEM simulation analysis of magnetic field and dynamic model of dual servo mechanism. These researches help to for decreasing loss in the air gap of VCM. We present dual servo mechanism is effective mechanism for a force control in hi h precision, properties of designed VCM.

• 한국정밀공학회지
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• 제17권4호
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• pp.22-28
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• 2000

By using the finite element method, the Oyane's ductile fracture integral I was calculated from the histories of stress and strain according to every element and then the forming limit of hydroforming process could be evaluated. The fracture initiation site and the forming limit for two typical hydroforming processes, tee extrusion and bumper rail under different forming conditions are predicted in this study. For tee extrusion hydroforming process, the pressure level has significant influence on the forming limit. When the expansion area is backed by a supporter and bulged, the process would be more stable and the possibility of bursting failure is reduced. For bumper rail, the ductile fracture integral i is not only affected by the process parameters, but also by the shape of preforming blank. Due to no axial feeding on the end side of the blank, the possibility of cracking in hydroforming of the bumper rail is influenced by the friction condition more strongly than that of the tee extrusion. All the simulation results show reasonable plastic deformation, and the applications of the method could be extended to a wide range of hydroforming processes.

• 한국생산제조학회지
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• 제26권4호
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• pp.410-417
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• 2017

Hydro-forming is being employed increasingly to realize lightweight vehicular parts. The bumper beam produced by this process weighs 30% less than the conventional products with equal stiffness. However, hydro-forming involves complex parameters to obtain the target geometry and low residual stress. Parametric studies are conducted using finite element analysis to obtain optimized process conditions. Through these numerical approaches, the internal and holding pressures and feeder forward stroke along the extruded direction are optimized to achieve low residual stress and to minimize springback. The numerical results are verified by experimental observations made by employing a three-dimensional laser scanner. The numerical and experimental results are compared in terms of the springback. Both results show similar tendencies.