• Transactions of Materials Processing
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• v.12 no.1
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• pp.49-59
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• 2003

To reduce the cost of finite element analyses for sheet forming, a 3D hybrid membrane/shell method has been developed to study the springback of anisotropic sheet metals. In the hybrid method, the bending strains and stresses were analytically calculated as post-processing, using incremental shapes of the sheet obtained previously from the membrane finite element analysis. To calculate springback, a shell finite element model was used to unload the final shape of the sheet obtained from the membrane code and the stresses and strains that were calculated analytically. For verification, the hybrid method was applied to predict the springback of a 2036-T4 aluminum square blank formed into a cylindrical cup. The springback predictions obtained with the hybrid method was in good agreement with results obtained using a full shell model to simulate both loading and unloading and the experimentally measured data. The CPU time saving with the hybrid method, over the full shell model, was 75% for the punch stretching problem.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.62-65
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• 1999

To reduce the cost of finite element analyses for sheet forming a 3D hybrid membrance/sheel method has been developed to study the springback of anisotropic sheet metals. in the hybrid method the bending strains and stresses were analytically calculated as post-processing using incremental shapes of the sheet obtained previously from the membrane finite element analysis. To calculate springback a shell finite element model was used to unload the final shape of the sheet obtained from the membran code and the stresses and strains that were calculated analytically. For verification the hybrid method was applied to predict the springback of a 2036-T4 aluminum square blank formed into a cylindrical cup. the springback predictions obtained with the hybrid method was in good agreement with results obtained using a full shell model to simulateboth loading an unloading and the experimentally measured data. The CPU time saving with the hybrid method over the full shell model was 75% for the punch stretching problem.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.148-151
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• 2003

In order to achieve reliable but cost-effective crash simulations of stamped parts, sheet forming process effects were incorporated in simulations using the ideal forming theory mixed with the 3D hybrid membrane/shell method, while the subsequent crash simulations were carried out using a dynamic explicit finite element code. Example solutions performed for forming and crash simulations of I- and S-shaped rails verified that the proposed approach is cost-effective without sacrificing accuracy. The method required a significantly small amount of additional computation time, less than 3% for the specific examples, to incorporate sheet forming effects to crash simulations. As for the constitutive equation, the combined isotropic-kinematic hardening law and the non-quadratic anisotropic yield stress potential as well as its conjugate strain-rate potential were used to describe the anisotropy of AA6114-T4 aluminum alloy sheets.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.9
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• pp.7-13
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• 2008

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.5
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• pp.519-524
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• 2014

The use of light weight magnesium alloy offers significant potential towards improvement of the automotive fuel efficiency. However, the application of formed magnesium alloy components in auto-body structures is restricted due to the low formability at room temperature and lack of knowledge for processing magnesium alloys at elevated temperatures. In this study, a warm tensile test of magnesium alloys was performed to measure tensile strength and elongation. An improvement in formability was confirmed at increased temperatures above about $250^{\circ}C$. Car body warm forming technology was conducted for forming forming reinforced dash components of the magnesium alloy AZ31B sheet at elevated temperatures.

• Journal of the Korea Safety Management & Science
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• v.7 no.1
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• pp.211-222
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• 2005

The ceramic forming materials are getting more important recently since they are used widely in repairing metal structures, welded metal structures and mechanical components etc. The determination of elastic constants for ceramic coating materials takes much time and efforts in experiment due to the brittleness of ceramic material itself. The aim of this research is to determine the Young's Modulus for ceramic metal coating material. In order to achieve the goal, the hybrid method which uses impulse hammer technique for experimental method and modal analysis of finite element method for computational method was used. The results show good agreement with existing experimental data on Young's Modulus.

• Transactions of Materials Processing
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• v.20 no.4
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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.

• Journal of the Korea Institute of Military Science and Technology
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• v.11 no.4
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• pp.83-91
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• 2008

The development of the equal channel angular pressing(ECAP) process in metals has recently provided a feasible solution to produce ultra-fine or nano-grained bulk materials with tailored material properties. However, ECAP process is difficult to scale up commercially due to requirements of an excessive load. In this paper, a new Hybrid-ECAP process with torsional die is considered to obtain materials of ultra-fine grain structure under low forming load. An upper bound analysis and numerical simulation (DEFORM 3D, a commercial FEM code) are carried out on the torsional die. By the upper bound analysis, analytical expression for the compression force and rotation speed are obtained. By the FEM analysis, the distribution of strain, stress and deformation are obtained. These results show that the Hybrid-ECAP is a useful process because this process can obtain the homogeneous deformations with relatively low forming load. Additionally, due to decreased forming load, die life can be improve.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2001.10a
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• pp.29-32
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• 2001

The objective of this work was to optimize processing parameters of hybrid thermoplastic composites in compression molding. The mechanical properties of the composites manufactured with various forming conditions were measured to characterize processing parameters. Polypropylene(PP) composites containing randomly oriented long carbon fiber and carbon black were used in this work. The composite materials contained 5%, 10%, 15%, and 20% carbon fiber and 5%, 10%, 15%, 20%, and 25% carbon black by weight. Compression molding was conducted at various mold temperatures. The temperature of the material in the mid-plain was monitored during the forming. Crystallinity was also measured by using XRD. The tensile modulus of the composites increase, with increasing the mold temperature. However, the impact strength of the composites decreases as mold temperature increases.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.11
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• pp.155-162
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• 2004

The volume of the metal is not changed for the plastic deformation. For metal forming simulation, rigid-plastic FEM codes are widely used. Updating geometry using Euler method in the simulation, the volume loss is occurred. In this paper, hybrid method is introduced to perform a more accurate simulation reducing computation time. In the proposed hybrid method, RK2 method is used for geometry updating at first time step and after the boundary condition of the node is changed. At the others, Adams-Bashforth or theta method is applied to update geometry. The results show that the simulations of upsetting and side-pressing can be performed within 0.02％.