• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.283-287
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• 2003

In recent years, design of an optimal blank shape is very important for sheet metal forming process in the automobile industry because the raw material cost rate is significant part in the automobile industry. With the design of an optimal blank shape, the engineer can protect a blank from an excessive holding force to improve the quality and reduce the ratio of material scrap. Therefore design of an optimal blank shape is inevitable in sheet metal forming process. However, if it causes a complicated shape of blank, it may be difficult to do the blank layout optimally. In this study, we developed software of optimal blank layout connected with the software of optimal blank shape design which was created in the past by the present authors. And by using these softwares, we would like to present the method in order to get optimal utilization ratio easily and precisely within short time for the sequence of works from design to blank layout.

• Transactions of Materials Processing
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• v.12 no.7
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• pp.615-622
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• 2003

In the automobile industry, the design of optimal blank shape becomes a significant part of the stamping. It provides many evident advantages, sush as enhancement of formability, reduction of material cost and product development period. However, the nesting process, required for the optimal usage of materials in the blanking becomes more complicated as the blank shape becomes complicated, like most optimal blank shape. In this study, stamping process optimization system for the optimal usage of material has been developed through the integration of optimal blank design and optimal nesting. For optimal blank design, a radius vector method, the modified version of the initial nodal velocity method, the past work of the present author, have been proposed. Both the optimal blank design and optimal nesting programs have been developed under the GUI environment for the convenience of engineers. The efficiency of the optimization system has been verified with some chosen problems.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03a
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• pp.45-48
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• 1999

The optimal blank design method by sensitivity analysis has been applied to the formings of oil-pan, tailored blank and front panel have been chosen as the examples. Die shape is prepared by a commercial CAD system. Excellent results has been obtained between the numerical results and the target contour shapes. Through the investigation, the proposed systematic method of optimal blank design is found to be effective in the practical forming processes.

• Transactions of Materials Processing
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• v.9 no.3
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• pp.226-232
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• 2000

The optimal blank design method by sensitivity analysis has been applied to the formings of oil-pan, tailored blank and front panel as the examples. Die geometry is prepared by a commercial CAD system. Excellent results has been obtained between the numerical results and the target contour shapes. Through the investigation, the proposed systematic method of optimal blank design is found to be effective in the practical forming processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.141-145
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• 2000

A systematic method to find the optimal blank shape for sheet forming is proposed by coupling the numerical simulation technique. A weighted parameter was introduced in order to simplify the multi-variable optimization problem to a single-variable problem. The proposed method has been applied to the blank design of drawing processes to obtain the near-net shape within the required error bound after forming, Excellent results have been obtained between the numerical results and the target contour shapes. Through the investigation the proposed systematic method for optimal blank design is found to be effective in the practical forming processes

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.77-81
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• 2002

A new method of optimal blank shape design using the initial nodal velocity (INOV) has been proposed for the drawings of arbitrary shaped cups. With the given information of tool shape and the final product shape, corresponding initial blank shape has been found from the motion of boundary nodes. Although the sensitivity method, the past work of Hynbo Shim and Kichan Son, has been proved to be excellent method to find optimal blank shapes, the method has a problem that a couple of deformation analysis is required at each design step and it also exhibits an abnormal behaviors in the rigid body rotation prevailing region. In the present method INOV, only a single deformation analysis per each design stage is required. Drawings of practical products as well as oil-pan have been chosen as the examples. At every case the optimal blank shapes have been obtained only after a few times of modification without predetermined deformation path. The deformed shape with predicted optimal blank almost coincides with the target shape at every case. Through the investigation the INOV is found to be very effective in the arbitrary shaped drawing process design.

• Transactions of Materials Processing
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• v.11 no.6
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• pp.487-494
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• 2002

A new method of optimal blank shape design using the initial nodal velocity (INOV) has been proposed for the drawings of arbitrary shaped cups. With the given information of tool shape and the final product shape, corresponding initial blank shape has been found from the motion of boundary nodes. Although the sensitivity method, the past work of the present authors, has been proved to be excellent method to find optimal blank shapes, the method has a problem that a couple of deformation analysis is required at each design step and it also exhibits an abnormal behaviors in the rigid body rotation prevailing region. In the present method INOV, only a single deformation analysis per each design stage is required. Drawings of practical products as well as oil-pan, have been chosen as the examples. At every case the optimal blank shapes have been obtained only after a few times of modification without predetermined deformation path. The deformed shape with predicted optimal blank almost coincides with the target shape at every case. Through the investigation the INOV is found to be very effective in the arbitrary shaped drawing process design.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.1 s.173
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• pp.79-86
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• 2000

In this study, a method of optimal blank design using the sensitivity analysis has been proposed. To get sensitivity a well-known commercial code PAM-STAMP has been used. In order to verify this method, formings of square cup, clover shaped cup and L shaped cup have been chosen as the examples. With the predicted optimal blank both computer simulation and experiment are performed. Excellent agreements are recognized between the numerical results and the target contour shapes. Through the investigation, the proposed systematic method of optimal blank design is found to be effective in the design of the deep drawing process.

• Transactions of Materials Processing
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• v.24 no.1
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• pp.28-36
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• 2015

After a short review of the iterative optimal blank method, a new method of measuring the shape error for stamped parts with 3D contour lines, which is an essential component of the optimal blank design, is proposed. When the contour line of the target shape does not exist in a plane, but exists in 3D space, especially when the shape of the target contour line is very complicated as in the real automotive parts, then the measurement of the shape error is critical. In the current study, a method of shape error measurement based on the minimum distance is suggested as an evolution of the radius vector method. With the proposed method, the optimal blank shapes of real automotive parts were found and compared to the results of the radius vector method. From the current investigation the new method is found to resolve the issues with the radius vector method.

• Transactions of Materials Processing
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• v.13 no.1
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• pp.90-101
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• 2004

An inverse mosaic method has been proposed to generate an initial blank shape from the final product shape. Differently from the geometric mapping method, the method can handle triangular patches. However, the generated blank shape is strongly dependent on the order of determination of nodes. In order to compensate the dependency error smoothing technique has been also developed. Although the accuracy has been improved greatly compared with the geometrical mapping method, the method has limitation, due to the no incorporation of plasticity theory. Even though the accuracy of the radius vector method is already proved. the method requires initial guess to start the method. In order to compromise the limitation of the present method and the radius vector method, the method has been connected to the radius vector method. The efficiency of the present optimal blank design method has been verified with some chosen examples.