• Transactions of Materials Processing
• /
• v.22 no.6
• /
• pp.323-327
• /
• 2013

In this paper, the flow lines as a function of product design as well as the forging process design are explored using typical application examples. The prediction of flow lines using metal forming simulation technology is introduced along with their characterization. Experimental studies have shown that the metal flow lines have a strong influence on the structural rigidity of the final product. In this study we present several typical applications. One example is the case of severely cut metal flow lines during machining, especially in the region where periodic contacting forces are applied. Another example is the case of abnormal distortion of flow lines which can cause too much elongation or hot shortness due to viscous heating in the region of distortion. A third example is the case of a macrosegregation region which needs to be controlled so it is not adjacent to the region where the force is applied in the use of the final component. An example of weight reduction for an automobile component with improved flow lines is also introduced. These typical applications can provide process engineers with the insight in designing automobile or mechanical components as well as in designing the manufacturing methods to produce various parts.

• Journal of Ocean Engineering and Technology
• /
• v.13 no.1 s.31
• /
• pp.29-38
• /
• 1999

In this paper the forming simulation of circular bulge by using PAM-STAMP has been performed to estimate the sheet metal forning and the plastic deformation characteristic of circular bulge. The uniaxial tension tests adn bulge tests are carried out for studying the forming characteristics of materials, and also Moire experiment are carried out for measuring the radius of curvature of the bulge and the polar compressive thickness strain. In order to compare the simulation results with the experiment and Hills theory, the relationships between redius of curvature adn polar height of the bulge, between hydraulic pressure and polar height, and between polar compressive thickness strain and polar height, are used. According to this study, the results of simulation and Hills theory are good agreement to the experiment. So, the results of simulation by using PAM-STAMP and Hills theory will give engineers good information to assess the formagbility and plastic deformation characteristic of hydraulic circular bulge test.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1994.06a
• /
• pp.25-36
• /
• 1994

The sheet metal forming process is one of the most important manufacturing processes in the modern industry. From the view point of mechanics involved, it is very difficult to predict whether a newly designed sheet metal part can be formed without defects such as fracture, wrinkling and surface unevenness, etc. In order to reduce the effort taken in the trial-and-error process and to control the process effectively, a systematic method for process modeling is to required. The aim of sheet forming simulation through the process modeling is to reduce the lead time for die disign and manufacture by process modeling is to reduce the lead time for die design and manufacture by means of investigating the deformation mechanics and the mutual interaction between the process parameters. In this paper, the necessity, the present status, and the future technology about CAE of sheet forming simulation have been discussed.

• Transactions of Materials Processing
• /
• v.15 no.3 s.84
• /
• pp.189-194
• /
• 2006

In this paper, an automated adaptive mesh generation scheme, based on an advancing-front-Delaunay method, is presented fur finite element simulation of three dimensional bulk metal farming processes. Basic approach is introduced in detail, including a surface meshing and volume meshing technique and a mesh density control scheme. The presented approach is applied to automatic forging simulation in order to evaluate the effect of the developed schemes. Comparison shows a good agreement between required mesh density and generated mesh density, implying that the presented approach is appropriate for automatic mesh generation in metal forming simulation.

• Transactions of Materials Processing
• /
• v.26 no.3
• /
• pp.168-173
• /
• 2017

A new sheet metal forming process, called flexibly reconfigurable roll forming (FRRF), is expected to resolve the economical limitation of the existing 3D curved sheet metal forming processes. The height-controllable guides and a couple of flexible rollers are utilized as the forming tool. Recently, as the 3D curved sheet metal is increasingly demanded in various fields, the application of FRRF to diverse materials is necessary. In addition, the formability comparison of several materials is needed. Therefore, in this study, we investigated the applicability of FRRF for different materials such as aluminum, magnesium, and copper alloys, and also the formability of these materials was compared using FRRF. The numerical simulation was conducted using ABAQUS, the commercial software, and the experiments were carried out using an FRRF apparatus to validate the simulation results. Finally, the applicability of FRRF for the chosen materials and the formability of these materials on FRRF process were confirmed by comparing the simulation and experimental results.

• Transactions of Materials Processing
• /
• v.16 no.4 s.94
• /
• pp.276-281
• /
• 2007

The hardening and the constitutive equation based on the crystal plasticity are introduced for the numerical simulation of hemispherical sheet metal forming. For calculating the deformation and the stress of the crystal, Taylor's model of the crystalline aggregate is employed. The hardening is evaluated by using the Taylor factor, the critical resolved shear stress of the slip system, and the sum of the crystallographic shears. During the hemispherical forming process, the texture of the sheet metal is evolved by the plastic deformation of the crystal. By calculating the Euler angles of the BCC sheet, the texture evolution of the sheet is traced during the forming process. Deformation texture of the BCC sheet is represented by using the pole figure. The comparison of the strain distribution and punch force in the hemispherical forming process between the prediction using crystal plasticity and experiment shows the verification of the crystal plasticity-based formulation and the accuracy of the hardening and constitutive equation obtained from the crystal plasticity.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2005.05a
• /
• pp.209-214
• /
• 2005

In this paper, finite element simulation of three-dimensional bulk metal forming processes is performed by an automated adaptive tetrahedral mesh generation scheme. A dynamic data exchange scheme is employed between tetrahedral mesh generator and forging simulator to minimize user intervention. Both number of elements and density distributions are controlled by the octree technique. The presented approach is applied to automatic forging simulation in order to evaluate the efficiency of the developed schemes and the simulation results are compared with $DEFORM^{TM}$.

• Transactions of Materials Processing
• /
• v.29 no.2
• /
• pp.76-88
• /
• 2020

The need for advanced high strength steel (AHSS) forming technology is increasing as interest in light weight and safe automobiles increases. Multipoint dieless forming (MDF) is a novel sheet metal forming technology that can create any desired longitudinal and transverse curvature in sheet metal. However, since the springback phenomenon becomes larger with high strength metal such as AHSS, predicting the required MDF to produce the exact desired curvature in two directions is more difficult. In this study, a prediction model using artificial neural network (ANN) was developed to predict the springback that occurs during AHSS forming through MDF. In order to verify the validity of model, a fit test was performed and the results were compared with the conventional regression model. The data required for training was obtained through simulation, then further random sample data was created to verify the prediction performance. The predicted results were compared with the simulation results. As a result of this comparison, it was found that the prediction of our ANN based model was more accurate than regression analysis. If a sufficient amount of data is used in training, the ANN model can play a major role in reducing the forming cost of high-strength steels.

• Transactions of Materials Processing
• /
• v.3 no.3
• /
• pp.359-374
• /
• 1994

Process sequence design in sheet metal forming process by the finite element method is investigated. The forming of sheet metal into a washing machine container is used to demonstrate the design of an improved process sequence which has fewer operations. The design procedure makes extensive use of the finite element method which has simulation capabilities of elastic-plastic modeling. A one-stage process to make an initial blank to the final product is simulated to obtain information on metal flow requirements. Loading simulation for a conventional method is also performed to evaluate the design criteria which are uniform thickness distribution around the finished part and maximum punch load within limit of available press capacity. The newly designed sequence has two forming operations and can achieve net-shape manufacturing, while the conventional process sequence has three forming operations. This specific case conventional process sequence has three forming operations. This specific case can be considered for application of the method and for development of the sequence design methodology in general.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2005.05a
• /
• pp.203-208
• /
• 2005

In this paper, an automated adaptive mesh generation scheme, based on an advancing-front-Delaunay method, is developed for finite element simulation of three dimensional bulk metal forming processes. During the simulation, the finite element mesh system is adaptively remeshed whenever the mesh is unacceptable. Several schemes are developed such as curvature compensation scheme to minimize volume loss, optimal smoothing scheme to improve element quality, etc. The presented approach is evaluated and applied to automatic forging simulation in order to demonstrate the effect of the developed schemes.