• Journal of the Korean Society for Precision Engineering
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• v.1 no.3
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• pp.71-84
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• 1984

This paper examined strain distribution and radius of curvature of the bulge by finite element method and investigated limit polar thickness strain to predict the formability of sheet metal as we substituted effective strain and the radius of curvature obtained by FEM into instability condition equation successively. In experiment, the radius of curvature and limit polar thickness strainwere obtained by Moire method. Also, a concent- ric set of photogrid circles was used to measure the strain of arbitrary point and mild steel was used as material. This results obtained are as follows: 1) The radius of curvature obtained by FEM is in good agreement with the Moire experimental value. 2) The polar thickness strain is getting larger as the inside is approached from the edge. This means that fracture occurred near the ploe. 3) The circumferential strains agree closely with the meridian strains and the polar thickness strain is about twice the circumferential (or meridian) strain. This result agrees with the fact that anisotropy coefficient (R-value) obtained by tensile test is about one. 4) The theoretical results of limit polar thickness strain obtained by authors' method are better agreement with experimental results than other theoretical results. Therefore, we can better predict the formability of sheet metal with authors' method.

• Transactions of Materials Processing
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• v.10 no.2
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• pp.91-100
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• 2001

A sectional FEA program is developed lot analyzing forming processes of sandwich sheets, which are intensively used recently as a lightweight material of an automobile body. The aluminum sandwich sheet consists of two aluminum skins and a polyprophylen core in between. The aluminum sandwich sheet is dominantly effected by the bending effects in small radius of curvature, so that an appropriate description of bending effects is required to analyze the forming processes. For the evaluation of bending effects, the bending equivalent forces are calculated from the bending moment computed using the curvature of the tool and are added to the membrane stretch forces. To verify the validity of the developed program the sectional FEA results in stretch/draw forming Processes of a square cup and draw forming Processes of an outer hood panel were compared with the measurements.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.4
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• pp.58-67
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• 1998

A sectional analysis of sheet metal forming process with an arbitrary tool shape is proposed in the present work. To improve the numerical convergence in the conventional membrane sectional analysis, the Bending Energy Augmented Membrane (BEAM) elements had been developed. The BEAM elements particularly improve the stability and convergence of the finite element method for the case of deep drawing. In this work, the FERGUBON spline (C$^2$-continuous) was used to fit the deformed mesh to smooth the given curves and calculate the local curvature of the deformed sheet. The fittings of the deformed sheet and tool surface profile ensure the stability and the convergence of the finite element analysis of highly nonlinear stamping processes. A center floor section and front fender section are analyzed to show the accuracy and robustness of the approach. The results obtained by the proposed approach are compared with the available experimental data.

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

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.322-325
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• 2005

In order to make a doubly-cowed sheet metal effectively, the sheet metal forming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation in thickness. The developed process is an unconstrained forming process without holder. The experimental equipment has been set up with the roll set which consists of two pairs of support rolls and one center roll. In order to analyze process parameters in the incremental roll forming process for the application to doubly curved ship hull plate, the orthogonal array is adopted. From the FEM results, among the process parameters, the distance between supporting rolls in pairs along the direction of one principal radius of curvature as well as the forming depth 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 principal radius of curvature, does not have an significant effect on the generation of the curvature in that direction. Also, the forming load and torque from the FEM simulation are acceptable to the system development of the incremental roll forming process for the forming of ship hull plate.

• International Journal of CAD/CAM
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• v.6 no.1
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• pp.199-211
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• 2006

Practical automated flat pattern generation with inbuilt production features for doubly curved sheet metal components (SMCs) is addressed here utilizing a new and unique Point Transformation Algorithm (PTA). This is the third in the series of papers on practical Flat Pattern Development (FPD) [8] and Production Loft Generation Systems (PLGS) [9] complementing the pioneering work [6,7]. In the first two publications, automated loft generation programs have addressed sheet metal components having a Principal Flat Surface (PFS) only. The flat pattern development of 3-D components that do not have the flat surface(termed as Non-PFS components) having complex features of double curvature in addition to cutouts and nibbled holes typical of aircraft components were so far not addressed due to lack of relevant published algorithms. This paper traces the evolution of developments and provides the record of fully illustrated, automated loft generation scheme for aircraft SMCs including the Non-PFS components which underwent validation through production tests by sponsors. Details of some of the unique features of the system like simplified surface model generation, termed as topological model and powerful algorithms deployed with potential for CAD/CAM applications are included.

• Tribology and Lubricants
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• v.28 no.5
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• pp.240-245
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• 2012

In this study, we developed a new carrier finger to prevent scratches in a sheet metal forming line. The developed carrier finger was designed to have a streamlined shape with a larger radius of curvature at the edges, as well as a smaller contact area. To evaluate the scratch alleviation effect, a sliding contact analysis and scratch test using the pin on a plate wear tester were conducted for both the old and new carrier fingers. The results show that, for both transverse and longitudinal movements of the strip, the newly designed carrier finger reduces both the friction and scratch depth by its streamlined shape, which decreases the pressure spike at the edge.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.241-244
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• 2009

This paper deals with a usefulness verification of stretch forming process using flexible die. The stretch forming method is widely used in aircraft and high-speed train industries for manufacturing of skin structure, which is made of sheet metal. A great number of solid dies are originally used and developed for specific shapes with respect to different curvature radii of the skin structures. Accordingly, flexible stretch forming process is proposed in this study. It replaces the conventional solid dies with a set of height adjustable discrete punches. A usefulness of the flexible die is verified through extensive numerical simulations of the stretch forming process for simply curved sheet plate. The elastic recovery is considered and formability evaluations are conducted through a comparison of symmetry plane configurations.

• Journal of Ocean Engineering and Technology
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• v.12 no.2 s.28
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• pp.57-64
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• 1998

This study is concerned with criterion for membrane to shell conversion in two-dimensional elastic-plastic finite element analysis using membrane/shell mixed element. It is well known that in the sheet metal forming some parts of the sheet deform under almost pure stretching (membrane) conditions, whereas other parts in contact with sharp tooling surfaces can develop significant bending strains. The membrane analysis has a short computational time however, in the membrane analysis the bending effects can not be condidered at all. On the other hand, the shell analysis allows the consideration of bending effects, but involves too much computational time. So Onatel),2), Yang et al3),4) developed the membrane/shell mixed element. Onate introduced the energy ratio parameter and Yang et al introduced the ratio of thickness to radius of curvature as the criterion. In the present study we propose a new criterion by using the angle between both side elements in the nodal point.

• Journal of the Korean Society for Precision Engineering
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• v.33 no.11
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• pp.911-918
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• 2016

A conical roll-shaping process was proposed for fabrication of a metallic spiral blade applied to a small-scale wind turbine system. A spiral blade has continuously different curvatures, with a range of 100 to 350 mm radius. To fabricate this complex shape, we developed a conical roll-shaping process having two main conical rollers for feeding a blank sheet, and two cylindrical side rollers for control of local bending. For clear understanding of the process parameters, numerical analyses were conducted using a commercial code, Pam-Stamp. This study optimized the effects of process parameters, such as gap and angle between the main rollers and side rollers, and also the movement of side rollers. In order to increase the forming efficiency, a central rotation point was also calculated by the analytical approach. This developed rolling process can thus be utilized in a sheet metal forming process for obtaining spirally curved sheet metal shapes.