• Transactions of Materials Processing
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• v.20 no.6
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• pp.420-426
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• 2011

Dent resistance is determined by both shape characteristics, i.e., local radius of curvature and sheet thickness, and material properties such as yield strength. This work presents results of a study on the effect of work hardening and bake hardening on dent resistance of aluminum alloy sheet parts by considering the forming condition and baking temperature.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.1
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• pp.42-49
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• 2016

This study was analyed V-bending in order to analyze the spring-back phenomenon in the roll forming process. The material of forming sheet used in the roll forming process is high tension steel and the product name of sheet material is POSTEN 60. The most important variable is the number of roll passes (3-Pass, 4-Pass, 5-Pass, 6-Pass and 10-Pass) and other roll forming process variables were fixed. To determine the characteristics of the tension and compression, the forming sheet was analyzed by dividing the layer (Upper and Bottom) in the thickness direction from the center line. The results of FEM simulation analysis was derived to von-mises stress equivalent strain, and the spring-back value was calculated according to the final forming shape. The more number of the roll pass, von-mises stress and equivalent strain value of forming sheet were lowed. Also, spring-back values tended to decrease. The results of this study can be utilized for prediction and trend of spring-back value in the roll forming process applied to high tension steel sheet. So, development time and cost of the roll forming process is expected to be reduced.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.8
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• pp.51-59
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• 2019

Flow forming is an eco-friendly and high-efficiency plastic deformation process with fewer chips during a process which is specifically used to manufacture seamless tubular products like tire wheels, rocket motor cases etc. On the development of mortar barrel using Inconel718 tube, some flow formed products had dimensional errors on their thickness. In this study, our purpose is to optimize the process conditions with the smallest dimensional error. In order to find an optimum process condition, 2D axisymmetric FEM simulation analyses with Taguchi method were conducted. Geometric variables (attack angle, flatting angle, roller nose radius) and operating parameters (depth of forming, feed rate) are considered as control factors. Forward flow forming with single roller was first analyzed to determine the effective factors using AFDEX software and attack angle of the roller was identified as the most influential factor. Also, the nose radius of the rollers was confirmed as a significant factor in multi-rollers flow forming system. The effect of rollers offset values are also studied and finally, we proposed optimal conditions to improve the accuracy of flow forming process with Inconel718 tube for mortar barrel manufacturing.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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• pp.39-45
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• 2022

In this study, we investigated whether the interference occurring in forming roll surfaces could be eliminated by increasing the radius of the variable section forming rolls. The surfaces of the rolls capable of forming products with different flange heights and bend angles with the bend line tilted at an angle of 1° from the longitudinal axis were created using the general CAD software CATIA. Roll interferences were determined for the change in the forming roll radius. The minimum gaps between the upper and lower roll surfaces were measured for the change in the forming roll radius, and the roll interferences were calculated from the difference between the measured value and the thickness of the product. It was observed that the thickness of the product had a slight effect on the roll interference when the thickness was between 0.8 and 1.2 mm. It was also observed that the roll interference could be eliminated by increasing the roll radius.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.37 no.12
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• pp.1201-1208
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• 2009

Dome stretching tests and tension tests were performed to evaluate the formability of a copper alloy used for manufacturing the regenerative cooling chamber. The test specimens were prepared to investigate the effect of heat treatment and direction of specimens on the formability. The test results show that forming limit values are increased by the heat treatment of the material but the variation of the forming limit values by manufacturing direction is negligible compared to the heat treatment effect, and forming limit values are also different according to the test methods. These results indicate that the high temperature heat treatment of the material before bulging is a very important process to deform the inner cylindrical structure of the regenerative cooling chamber into a nozzle shape by the bulging process without necking or fracture and the test methods also have a great effect on a evaluation of the formability. The forming limit diagram obtained in this study would be utilized to the design of regenerative cooling chamber nozzles.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.10a
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• pp.559-560
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• 2012

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.10a
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• pp.141-142
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• 2006

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.30.1-33
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• 1999

Finite element simulation with experimental analysis of Taguchi's orthogonal array was carried out to know the effects of material and forming parameters on the cup earing and skewness. It was revealed that the planar anisotropy was the most influencing factor in the cup ear formation whereas blank holding force and material properties such as strength and thickness deviation at the coil edge had a relatively high effect on the cup skewness.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.395-395
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• 2008

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.1
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• pp.29-36
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• 2008

In this paper, the orbital forming analysis of an automotive hub bearing was studied to predict forming performances using the explicit finite element method. To find an efficient solution technique for the orbital forming, axisymmetric finite element models and 3D solid element models were solved and numerically compared. The time scaling and mass scaling techniques were introduced to reduce the excessive computational time caused by small element size in case of the explicit finite element method. It was found from the numerical simulations on the orbital forming that the axisymmetric element models showed the similar results to the 3D solid element models in forming loads whereas the deformations at the inner race of bearing were quite different. Finally the strains at the inner race of bearing and the forming forces to the peen were measured for the same product of the numerical model by test, and were compared with the 3D solid element results. It was founded that the test results were in good agreements with the numerical ones.