• Title/Summary/Keyword: Forming Process

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Development of Manufacturing Technology for Center Floor Cross Member with Roll Forming Process (롤 포밍 공법을 이용한 고강도 차체 부품 제작 기술 개발)

  • Kim, D.K.;Park, S.E.;Cho, K.R.;Lee, K.H.;Kim, K.H.;Lee, M.Y.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2009.10a
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    • pp.297-300
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    • 2009
  • The roll forming process is often used to manufacture long, thin-walled products such as a pipe. The final cross-section is a comparatively simple open-channel, a closed tube section or a complex profile with several bends. In recent years, that process is often applied to the bumper beam in the automotive industries. In this study, a optimal Center Floor Cross Member manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle, and also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

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Development of The Multi Forming Type Ultra Precision Die for Sheet Metal ( Part I )- Production Part and Strip Process Layout -

  • Sim, Sung-Bo;Jang, Chan-Ho;Sung, Yul-Min
    • Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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    • 2001.10a
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    • pp.253-257
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    • 2001
  • This study reveals the sheet metal working with multi-forming type ultra precision process. They require analysis of many kinds of important factors, i.e. theory and practice of metal press working and its phenomena, die structure, machining condition for die making, die material, heat treatment of die components, know-how and so on. In this study, we designed and constructed a multi-forming ultra precision progressive die as a bending and drawing working of multi-stage and performed through the try out for thin sheet metal. This part I of papers related to the analysis of production part and strip process layout design through the metal forming simulation by DEFORM and IDEAS.

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Blank Design and Strain Prediction in Sheete Metal Forming Process (박판금속 성형공정에서의 블랭크 설계및 변형률 예측)

  • Lee, Choong-Ho;Huh, Hoon
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.20 no.6
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    • pp.1810-1818
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    • 1996
  • A new finite elemetn approach is introduced for direct prediction of bland shapes and strain distributions from desired final shapes in sheet metal forming. The approach deals with the geometric compatibility of finite elements, plastic deformation theory, minimization of plastic work with constraints, and a proper initial guess. The algorithm developed is applied to cylindrical cup drawing, square cup drawing, and fron fender forming to confirm its validity by demonstratin reasonable accurate numerical results of each problems. Rapid calculation with this algorithm enables easy determination of various process variables for design of sheet metal forming process.

Finite Element Analysis of Orbital Forming Process in Bearing Manufacturing (베어링 제조공정중 궤도단조공정의 유한요소해석)

  • Moon H. K.;Lee M. C.;Chung J. H.;Joun M. S.
    • Transactions of Materials Processing
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    • v.14 no.1 s.73
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    • pp.29-36
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    • 2005
  • In this paper, a useful rigid-plastic finite element method with various numerical schemes is presented for simulation of an orbital forming process. A new approach to reduce volume change during simulation is presented and an approximation method to reduce computational time is also presented. An actual orbital forming process found in a bearing making industry is simulated by the presented approach. The simulated results of the orbital forming process are compared with the experimental results.

Roll Forming Analysis for High Strength Steel Bumper Process (고장력강 범퍼 빔의 롤 포밍 공정)

  • Kim, Dong Hong;Jung, Dong Won
    • Journal of the Korean Society for Precision Engineering
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    • v.30 no.8
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    • pp.797-801
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    • 2013
  • Today's automotive industry is evolving toward low-emissions or zero-emissions high-efficiency vehicles. Highly efficient power sources are required, as well as high strength steels for various parts to increase safety. In this study, we investigated the roll-forming process for the development of high strength, lightweight steel bumper beams. The roll-forming process was analyzed using the software package Shape-RF in combination with a rigid-plastic finite element method model. An optimal roll-forming process based on roll-pass was obtained using finite element method simulations.

SpringBack Prediction for Sheet Metal forming Process Using Shell Element (쉘 요소를 이용한 박판성형 공정의 스프링 백 예측)

  • Ko Hyung-Hoon;Lee Chan-Ho;Kim Byung-Sik;Lee Kwang-Sik;Jung Dong-Won
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2005.10a
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    • pp.402-405
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    • 2005
  • Such press-forming process are the used machine ability and the characteristic, used material, tile accuracy of the part, condition of a process are considered the designed. In order to estimate in automotive sheet forming processes used AutoForm software. A through in simulation result comparison with experimentation result, it was possible to know that much the same estimated spring-back through a forming analysis. By making apply this to an industrial site the productivity improvement and cost reduction etc. effect able was predicted.

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Design of Flower Pattern in Roll Forming Process for Ultra High Strength Bumper Beam (초고강도 범퍼 빔의 롤 포밍 공정을 위한 플라워 패턴 설계)

  • Cha, T.W.;Kim, J.H.;Kim, G.H.;Kim, B.M.
    • 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.

Multi-Filament Hydrostatic Extrusion and Fine Wire Dieless Stretching Technology (미세 다심선 정수압 압출 및 단선 무금형 신장 성형 기술)

  • Park, Hoon-Jae;Kim, Chang-Hoon
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.5 no.4
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    • pp.79-85
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    • 2006
  • Multi-filament hydrostatic extrusion was developed as a fine wire manufacturing process and wire forming experiments were conducted. Also, single wire stretch forming process was proposed in the possibility of obtaining long wire with constant cross-section. In the multi filament extrusion since the workpiece, die and forming facility are in the macro forming circumstance, fine wire and fine hole structure with less than a few micrometer can be easily obtained. Although stretch forming does not use a die in order to avoid the friction problem between the workpiece and the die, it is necessary to have high level of technology to maintain cross-sectional shape and measure in longitudinal direction.

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Use of a Drawing Process to Manufacture a Large-Size Dome Shaped Forging-Produts (드로잉 공정을 이용한 대형 반구 형상 제작에 관한 연구)

  • Lee, S.U.;Cho, J.R.;Yang, D.Y.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2008.05a
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    • pp.531-534
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    • 2008
  • A new forming process of the large-size forging within the limit of forming loads is developed by introducing the drawing process, which usually used to apply to sheet forming. For the development of the forming process, corresponding numerical simulation are carried out. The approach is based on the Taguchi method, and utilize the DOE for design of FEM analyses. In this study, the important factors are chosen at first, and then the concept of signal-to-nose(S/N) rate is applied to evaluate the formability of large size forging-products, and each value of the design parameter is determined.

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Experimental and Numerical Analyses of Flexible Forming Process for Micro Channel Arrays of Fuel Cell Bipolar Plates (연료전지 분리판의 마이크로 채널 제작을 위한 가변성형공정의 실험적 및 수치적 연구)

  • Kim, H.S.;Shim, J.M.
    • Transactions of Materials Processing
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    • v.21 no.8
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    • pp.499-505
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    • 2012
  • The fuel cell is a very promising power generation system combining the benefits of extremely low emissions, high efficiency, ease of maintenance and durability. In order to promote the commercialization of fuel cells, a flexible forming process, in which a hyper-elastic rubber is adopted as a medium to transmit forming pressure, is suggested as an efficient and cost effective manufacturing method for fuel cell bipolar plates. In this study, the ability of this flexible forming process to produce the micro channel arrays on metallic bipolar plates was first demonstrated experimentally. Then, a finite element (FE) model was built and validated through comparisons between simulated and experimental results. The effects of key process parameters on the forming performance such as applied load and punch velocity were investigated. As a result, appropriate process parameter values allowing high dimensional accuracy without failure were suggested.