• 소성∙가공
• /
• 제26권4호
• /
• pp.222-227
• /
• 2017

In order to respond to environmental regulations and increased demand for fuel economy, the demand for lightweight car bodies has grown. Hydroforming of aluminum is one possible solution as it eliminates the need for additional welding to develop closed cross-sectional parts. However, the low formability of aluminum is a limitation of its application. On the other hand, the ductility of materials can be improved at higher temperatures, and hot metal gas forming has been widely applied in the production of lightweight vehicle parts. In this study, aluminum alloy for pipe extrusion was developed by controlling the Mg:Cr:Mn ratio based on AA5083. Mechanical properties of the developed material were examined by tensile test and were applied to a forming simulation. Cold forming simulation for preforming and non-isothermal hot forming simulation for hot metal gas forming were carried out to validate process conditions. A prototype of the sidemember was manufactured under the given process condition. Finally, thickness distribution was compared with finite element analysis results.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2003년도 제4회 박판성형 심포지엄
• /
• pp.53-57
• /
• 2003

In order to make a doubly curved sheet metal effectively, a sheet metal farming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation to thickness. The developed process is an unconstrained forming process with no holder. For this study, the experimental equipment is set up with the roll set which consists of two pairs of support rolls and one center roll. In the experiments using aluminum sheets, it is found that the curvature of the formed sheet metal is determined by controlling the distance between supporting rolls in pairs and the forming depth of the center roll and it also depends on the thickness of the sheet metal. In order to check the effect of process parameters on the generation of sheet metal curvatures in this process, the orthogonal array is adopted. From the experimental results, among the process parameters, the distance between supporting rolls in pairs along the same direction of one principle radius of curvature as well as the forming depth and the thickness of the material is shown to influence the generation of curvature in the same direction significantly. That is, the other distance between supporting rolls in pairs which are not located in the same direction of one principle radius of curvature, does not have an significant effect on the generation of the curvature in that direction. It just affects the generation of curvature in its own direction mainly with the forming depth and the thickness of the material.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2009년도 추계학술대회 논문집
• /
• pp.281-284
• /
• 2009

Flexible forming process for sheet metal using reconfigurable die is introduced based on numerical simulation. Numerical simulation of sheet metal forming process is carried out by using flexible dies model instead of conventional matched die set. Elastic cushion which has high resilience behavior from excessive deformation are inserted between forming punches and blank material for smoothing the forming surface which has discrete due to characteristics of the flexile die. As an elastic cushion, urethane pads are utilized using hyperelastic material model in the simulation. Formability in view of surface defect such as onset of dimple is compared with regard to various punch sizes. Consequently, it is confirmed that the flexible forming process for sheet material has appropriate capability and feasibility for manufacturing of smoothly curved surface instead of conventional die forming process.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 1999년도 춘계학술대회논문집
• /
• pp.245-248
• /
• 1999

Explicit dynamic finite element analysis has been used widely in the field of sheet metal forming. However in using the analysis technique there are some parameters which are not clearly defined so that engineers may obtain inaccurate solutions In the present study parameters such as time step damping ratio penalty constant and punch speed were investigated on their influence to the solution behavior. Considered forming processes are plane stain bending by a punch and axisymmetric deep drawing.

• 한국생산제조학회지
• /
• 제23권5호
• /
• pp.512-518
• /
• 2014

In this paper, the influence of part shape complexity and die type on forming accuracy in incremental sheet metal forming is presented. The part shape complexities are classified into two types, namely, of one and two-step shapes. Correspondingly, die types are classified into three types, namely, of no-, partial, and full die types. The experimental tests are performed separately on negative and positive forming methods. It is shown that for the one-step shape, there are no significant differences in forming errors between the cases of no- and full die types when the negative forming method is used. Furthermore, the full die type is better than the partial die when positive forming is used. For the two-step shape case, the full die type always exhibits better forming accuracy than the no- and partial die types, irrespective of the forming method used.

• 소성∙가공
• /
• 제9권3호
• /
• pp.233-241
• /
• 2000

It is well known that the quality and efficiency of the design of metal forming processes can be significantly improved with the aid of effective numerical simulations. In the present study, a two-and three-dimensional finite element simulation system, CAMP form, was developed for the analysis of metal forming processes in the PC environment. It is composed of a solver based on the thermo-rigid-viscoplastic approach and graphic user interface (GUI) based pre-and post-processors to be used for the effective description of forming conditions and graphic display of simulation results, respectively. In particular, in the case of CAMPform 2D (two-dimensional), as the solver contains an automatic remeshing module which determines the deformation step when remeshing is required and reconstructs the new mesh system, it is possible to carry out simulations automatically without any user intervention. Also, the forming analysis considers ductile fracture of the workpiece and wear of dies for better usage of the system. In the case of CAMPform 3D, general three-dimensional problems that involve complex die geometries and require remeshing can be analyzed, but full automation of simulations has yet to be achieved. In this paper, the overall structure and computational background of CAMPform will be briefly explained and analysis results of several forming processes will be shown. From the current results, it is construed that CAMPform can be used in providing useful information to assist the design of forming processes.

• 대한기계학회:학술대회논문집
• /
• 대한기계학회 2001년도 춘계학술대회논문집C
• /
• pp.100-105
• /
• 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.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 1997년도 춘계학술대회논문집
• /
• pp.46-49
• /
• 1997

During sheet metal forming on a double-action press, drawbeads on the blankholder supply a restraining force which controls the flow of metal into the die. The sheet formability can be improved by the optimum drawbeads installation when the punch enters into the die opening. Experiments on the various drawbeads, circular, step, double circular, and circular-step drawbead, have been performed under various working conditions.

• 소성∙가공
• /
• 제11권3호
• /
• pp.223-230
• /
• 2002

Matched die forming technology has been used widely as a sheet metal forming method for a long time. This conventional method, however, needs a high cost and long delivery time to prepare a set of matched dies or, in many cases, several sets of dies. For more than ten years, some alternative methods using single die or non-matched dies have been developed and applied practically in various fields of industry. Elasto-forming, fluid forming, hydro-forming, and blow forming are some examples of these new methods. Recently, a dieless sheet forming technology using a reconfigurable matrix of punch elements has been developed, and started to be used in some industries such as aircraft and railroads. A new concept of dieless forming technology has also been proposed to overcome the drawback of the conventional dieless forming technology.

• 소성∙가공
• /
• 제26권2호
• /
• pp.79-86
• /
• 2017

In this study, the sheet metal forming process of the brake chamber head, which had a complex shape compared to the conventional head part, was investigated using finite element (FE) analysis. In order to prevent the forming failures such as necking and fracture, the multi-stage forming process was introduced. The forming process consisted of three steps: (1) first drawing, (2) second drawing, (3) final forming. Experimental and FE simulated results of the brake chamber head were compared, and the results showed that the required characteristics of the straightness and the wall thickness at each location were satisfied.