• Transactions of Materials Processing
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• v.17 no.8
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• pp.570-578
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• 2008

A flexible forming apparatus is composed a number of punches which have spherical pin tip shape instead of conventional solid die. The flexible forming tool consisted of punch array in a matrix form was proposed as an alternative forming method to substitute the conventional line heating method which use heat source to induce residual stress along specified heating lines. In this study, application of the flexible forming process to the small scale curved plate forming was conducted. Numerical simulations for both solid and flexible die forming process were carried out to compare the shape of the products between flexible and conventional die forming process. In addition, spring-back analysis was conducted to figure out the feasibility of the flexible forming process comparing with the die forming process in view of final configuration of the specimens. Moreover, experiment was also carried out to confirm the formability of the process. Consequently, it was confirmed that the flexible die forming method has capability and feasibility to manufacture the curved plates for shipbuilding.

• Transactions of Materials Processing
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• v.9 no.6
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• pp.670-680
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• 2000

The purpose of this study is to provide the database of forming limit diagram applicable to the warm forming of oil pan. The test materials are SCP1 and SCP3C with the thickness of 1.4mm which is used for the oil pan of automobile. The testing temperature is 5$^{\circ}C$~15$0^{\circ}C$ which is In the range of practical usage. The results are the forming limit diagram limiting dome height and the maximum punch load at each temperature such as 5$^{\circ}C$, $25^{\circ}C$, 6$0^{\circ}C$, 9$0^{\circ}C$, 12$0^{\circ}C$ and 15$0^{\circ}C$. From these results, we can see that the forming limit curves are translated depending upon the temperature and that FLC at low temperature is higher than at high temperature. Both of limiting dome height and maximum punch load also decrease as the temperature increases. Present results can be useful for die trial and forming analysis as a tool of evaluating the forming severity for the sheet metal forming processes at the warm working condition by comparing the practical strains with FLC.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.294-297
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• 2007

Due to their low densities and high specific strength and stiffness, magnesium alloy sheets are very attractive lightweight materials for automotive and electrical products. However, the magnesium alloy sheets are usually formed at elevated temperature because of their poor formability at room temperature. To use of the magnesium alloy sheets for an industrial, their mechanical properties at elevated temperature and appropriate forming process conditions have to be developed. In this study, non-isothermal simulations of a square cup drawing from magnesium alloy sheets have been conducted to evaluate a proper forming process conditions such as the tool temperature, the tool shoulder radius, friction between the blank and the tools. According to this study, appropriate forming process conditions of square cup drawing at elevated temperature from magnesium alloy sheets are suggested.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.195-199
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• 2001

The flow turning process, an incremental forming process, is a cost-effective forming method for axi-symmetric intricate parts to net shape. However, the flow turning process shows a fairly complicated deformation, it is very difficult to obtain satisfactory results. Therefore extensive experimental and analytical research has not been carried out. In this study, an fundamental experiment was conducted to improve productivity with process parameters such as tool path, angle of roller holder($\alpha$), feed rate(v ) and comer radius of forming roller(Rr). These factors were selected as variables in the experiment because they were most likely expected to have an effect on spring back. The clearance was controlled in order to achieve the precision product which is comparable to deep drawing one. And also thickness and diameter distributions of a multistage cup obtained by flow turning process were observed and compared with those of a commercial product produced by conventional deep drawing.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.2
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• pp.507-514
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• 1991

A penalty finite element method has been developed for accurately predicting stress distributions at the tool-workpiece interfaces. The basic formulation is described, with the emphasis on the algorithm to deal with the normal stress and the frictional stress at the interface. Comparison with the experimental data and the theoretical solutions found in the literature is made for the forming processes selected.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.159-163
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• 2003

In recent days, as the efficiency of electronic home applications become higher, that of the driving AC motor become higher. On this reason, the demand fir high capacity coil firming machine is increasing. Since the coil forming is not simply related with the only capacity of hydraulic cylinder, the development of a newer coil firming machine which has new filming mechanism new driving method, new filming tool, and new specification is required. In this paper, the virtual prototype which have new mechanism is developed. This prototype is tested and experimented on PC with the same condition as actual. The results from the virtual experiment is applied to the actual design process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.837-841
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• 2000

Spinning process is a chipless metal forming method for axi-symmetric parts, which is more economical, efficient and versatile method of producing parts than the other sheet metal forming process such as stamping or deep drawing. It is a point deformation process where a metal disc. cylinderical workpiece. or preform in contact with a rotating chuck is plastically deformed by axial or axial-radial Motions of a tool or roller. in this study the variation of spring back with respect to various forming roller corner radius(Rr) and angle of roller holder($\alpha$) is investigated. Good as a result will help to get more precise shape by control of spring back.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.26-29
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• 1999

The sectional forming analysis program for analyzing the hydroforming processes of axisymmetric sheet parts was tleveloped. The rigid-viscoplastic FEM formulation based on membrane theory was derived, wh~cta simi~ltaneously solve force equilibrium as well as non-penetration condition. Hill's non-quadratic normal anisotropic yield theory(1979) was used for material behaviour. For describing the liquid pressure iaction, the flexible tool concept was introduced. Isotropic hardening law was also assumed. To verify the \,alidity of the formulation, the stepped cup forming process as well as the hydrostatic bulging test were \imnlated. Simulation results agreed well with Finckenstein and experimental ones.

• Journal of the korean Society of Automotive Engineers
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• v.12 no.6
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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.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1980-1983
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• 2005

The characteristic of sheet metal process is the few loss of material during process, the short processing time and the excellent price and strength. The sheet metal process with above characteristic is common used in industrial field, but in order to analysis irregular field problems the reliable and economical analysis method is demanded. Finite element method is very effective method to simulate the forming processes with good prediction of the deformation behaviour. Among Finite element method, The static-implicit finite element method is applied effectively to analyze real-size auto-body panel stamping processes, which include the forming stage. In this paper, it was focussed on the drawability factors on auto-body panel stamping by AUTOFORM with using tool planing alloy to reduce law price as well as high precision from Design Optimization of ide. According to this study, the results of simulation will give engineers good information to access the Design Optimization of die.