• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.30.2-34
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• 1999

The hydroforming technology has gained in importance over the last few years, because of its potential for substantial weight avings costs reduction and quality improvement such as collision property, shape fixability and rigidity of white body. However, in comparison with the traditional sheet forming process, the hydroforming is much younger and the main development efforts were made in the last 15 years. The new technology, high pressure tublar hydroforming in particular, involves many process parameters to be optimized. This paper covers a brief overview of the hydroforming simulator as well as design of die and tools. The effects of typical parameters such as internal pressure and axial compression stroke are presented. Moreover, the conditions of forming failure occurrences such as fracture and wrinkle are examinated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.70-73
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• 2007

The forming characteristics of cup-rod combined extrusion process were investigated with process parameter change. Simultaneous forward rod extrusion and backward cup extrusion was conducted with magnesium alloy, AZ31B. Process parameters such as forward extrusion ratio, backward extrusion ratio, and working temperature were controlled in a specific region and the effects of the parameter change were examined. Surface crack was developed in a certain state of the process parameters combination. The crack-free forming limit of the alloy in the combined process was disclosed by the parameter study. The microstructures of the initial and extruded workpieces were observed.

• Design & Manufacturing
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• v.2 no.2
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• pp.43-47
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• 2008

This paper is concerned with the analysis of material flow characteristics of stepped rod forming. The analysis in this paper concentrated on the evaluation of the design parameters for deformation patterns of tube forming, load characteristics, extruded length, and die pressure. The design factors such as punch nose radius, die corner radius, friction factor, and punch face angle are involved in the simulation. The stepped rod forming is analyzed by using a commercial finite element code. This simulation makes use of stepped rod material and punch geometry on the basis of punch geometry recommended by International Cold Forging Group. As radius ratio is large, forming load was reduced but extruded length ratio was increased.

• Proceedings of the KWS Conference
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• 2005.06a
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• pp.91-93
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• 2005

Forming sheet metal by laser-induced thermal stresses (laser forming) has been extensively studied, and the research has focused on two-dimensional geometries using a multi-pass straight line scan. Recently there came out some useful studies or three-dimensional laser forming which is applied to doubly curved shapes. The task of 3D laser forming sheet metal is to determine a set of process parameters such as laser scanning paths, laser power and scanning speed that will make a given shape. New method for laser forming of a doubly curved surface by using geometrical information was proposed and verified by experiments. This method shows good performance in the sense of calculation time and accuracy compared to the inherent strain method.

• Journal of Welding and Joining
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• v.26 no.4
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• pp.66-72
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• 2008

Because of high intensity and easy controllability of the heat source, high frequency induction heating has been concerned and studied for the steel forming process in the ship building industry. However, the heating and forming characteristics have to be further properly modelled and analyzed for the process to be utilized with its optimal working parameters. In this study, a modelling with thermo-elasto-plastic analysis is performed using the FEM to study heat flow and deformation of the steel plate during the forming process with the electro-magnetic induction heating. The numerical model is then used to study the effect of the inductor shape on the magnitude of angular deformation of the plate during the forming process. It is revealed that the square shape of inductor induces the largest deformation among the rectangular inductors.

• Transactions of Materials Processing
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• v.12 no.4
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• pp.296-301
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• 2003

Though a glass tens has outstanding optical performance, it has not been widely used because manufacturing process shows poor productivity and high cost. However, press-forming method of glass lens overcomes these disadvantages with mass production. When glass lens is produced by press-forming method using closed die, it is needed that the volume of glass lens preform is precisely measured in order to prevent incomplete products and to increase in life of die. The present. paper shows the shortcoming of forming process with closed die, and performs FEM simulation of forming process with open die in order to overcome this shortcoming. The design parameters of open die are selected on the basis of assembly with optical module and maintenance of optical performance. FEM simulation is carried out with selected parameter of open die and two basic preform. According to distribution of effective strain in glass lens, optical property of glass lens formed at each set of die and preform is compared.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.419-422
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• 2005

Many process parameters have an effect on the auto-body panel forming process. A well-designed blank shape causes the material to flow smoothly, reduces the punch and yields a product with uniform thickness distribution. Therefore, the determination of an initial blank shape plays the important role of saving time and cost in the auto-body panel forming process. For these reasons, some approaches to estimate the initial blank shape have been implemented in this paper, the one-step approach by using a finite element inverse method will be introduced to predict the initial blank shape the developed program is applied to auto-body panel forming.

• Transactions of Materials Processing
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• v.11 no.6
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• pp.503-512
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• 2002

The drawbead is used to control material flow into the die during the binder wrap process and the stamping process in the sheet metal forming process. Since the dimension of drawbead is relatively small in comparison with the typical dimensions, it is difficult to include drawbeads in finite element analysis of the sheet metal forming process. It is because the mesh system has to be fine enough to describe the drawbead and the computation time is drastically increased. In this paper, simulation of drawbead forming has been carried out to obtain the equivalent boundary conditions in the binder wrap process and the stamping process. In order to investigate the effect of various die geometries, parameter studies are performed with the variation of parameters such as the blank length, the drawbead depth, the drawbead radius, the inclination of die and the friction coefficient.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.11
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• pp.1361-1370
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• 2012

A shape optimization is proposed to obtain the desired final shape of forming and forging products in the manufacturing process. The final shape of a forming product depends on the shape parameters of the initial blank shape. The final shape of a forging product depends on the shape parameters of the billet shape. Shape optimization can be used to determine the shape of the blank and billet to obtain the appropriate final forming and forging products. The equivalent static loads method for non linear static response structural optimization (ESLSO) is used to perform metal forming and forging optimization since nonlinear dynamic analysis is required. Stress equivalent static loads (stress ESLs) are newly defined using a virtual model by redefining the value of the material properties. The examples in this paper show that optimization using the stress ESLs is quite useful and the final shapes of a forming and forging products are identical to the desired shapes.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.100-105
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• 2001

The manufacturing of metal bellows consists of the four main forming processes, deep-drawing, ironing, tube bulging and folding. Among these, the bulging and folding processes are critically important because the quality of metal bellows is greatly influenced by the forming conditions of these processes. In the present study, the finite element analysis technique is applied to the bulging and folding processes to obtain information about the design parameters of a metal bellows.