• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.10a
• /
• pp.254-258
• /
• 2009

In this paper, the low frequency vibration forming system is developed for micro-patterns formation on the metal substrate. many researchers have studied about micro-forming technologies such as micro deep drawing, press forming, forging, extrusion etc. for the formation of precise micro-patterns on the surface of metal substrates, multi-step forming process must be used to improve qualifies of the deformed patterns. Since the low frequency vibration forming system could easily deform the surface of metal substrates, several steps of multi-step forming process should be removed by using the low frequency vibration forming system. In order to find optimal process conditions, we have carried out low frequency vibration forming process with varying the vibration frequency from 110Hz to 500Hz.

• Transactions of Materials Processing
• /
• v.13 no.5
• /
• pp.429-434
• /
• 2004

Manufacturing process for milli components has recently gained researcher's focus with the increasing tendency toward highly integrated and micro-scaled parts for electronic devices. The milli-components need more precise manufacturing process than the conventional manufacturing process since the parts require higher dimensional accuracy than the conventional ones. In order to enhance the forming accuracy and productivity, various forming procedures proposed and studied by many researchers. In this paper, forming analysis of milli-components has been studied with a new micro-former. In modeling of progressive dies, multi-stage forming sequence has been analyzed with finite element analysis by LS-DYNA3D. The analysis proposes the sequential die and part shapes with the corresponding punch force and dimensional accuracy. The analysis also considers the effect of elastic dies on the dimensional accuracy of the formed parts. The analysis result demonstrates that the elastic analysis in the milli-forming process is indispensable for accurate forming analysis. The analysis procedure in the paper will provide good information in design of a new micro-former and milli-component

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.71-74
• /
• 2008

In order to resolve the problems which appear after the clean large ingot production process, the impurities which are involved in the steel smelting process should be removed by developing cleaner materials. Through the rationalization of cogging process that is the first forging process of large ingot the quality is to be improved. For the sake of the optimization of an open die forging process and the improvement of the subject matter frequency ratio, a hazard precise die forging process must be developed and a Near Net Shape Forming accomplished. As a result, energy can be reduced by minimizing an after control process. In order to produce large axes and other forming parts, processing techniques are to be developed. In this context, this paper is a study about a reduction ratio, dies width ratio and rotary angles, the amount of overlap, and intends to analysis cogging processes, utilizing Deform-3D cogging module

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.11 no.1
• /
• pp.101-106
• /
• 2012

The press bulging process is very useful and productive method to produce round-type mechanical components which have not been able to be manufactured because of limitation of the conventional press technology. The application of the press bulging process has expanded very quickly in the hydraulic and electronic industry and more recently it has been used to produce other mechanical parts such as the automobile and shipping parts. This expanding application also has brought some unsolved problems and leads many researchers to put their effort into the die design of the press bulging process. In this study, to obtain the optimum die shape for the press bulging process, various process parameters have been considered such as corner radius, bulging height, pressing length, and forming load, etc. The main interest of this paper is to verify the press bulging process which has more than 4.0 in height-length ratio. From this aspect, Finite Element analysis shows great ability to simulate the precise deformation process and gives us manufacturing database. Consideration of strain, stress, and strain-rate for the various cases has been also taken to keep the forming load within a particular range.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.05a
• /
• pp.837-841
• /
• 2000

Spinning process is a chipless metal forming method for axi-symmetric parts, which is more economical, efficient and versatile method of producing parts than the other sheet metal forming process such as stamping or deep drawing. It is a point deformation process where a metal disc. cylinderical workpiece. or preform in contact with a rotating chuck is plastically deformed by axial or axial-radial Motions of a tool or roller. in this study the variation of spring back with respect to various forming roller corner radius(Rr) and angle of roller holder($\alpha$) is investigated. Good as a result will help to get more precise shape by control of spring back.

• Transactions of Materials Processing
• /
• v.13 no.2
• /
• pp.129-136
• /
• 2004

Recently, instead of a matched die forming method requiring a high cost and long delivery term, a multi-point dieless forming method using a pair of matrix type punch array as flexible dies has been developed. Since the conventional multi-point dieless forming method has some disadvantages of difficulty in precise punch control and high-cost of equipment, a new concept of multi-point dieless forming method combined with an elasto-forming method has been suggested in this study. For optimal selection of elastomers, compression tests of rubbers, polyethylene and foams were carried out together with FEM analysis of the deformation behavior during sheet forming process using a rigid punch and elastomers. Compressive strain was concentrated on the upper central area of the elastomer under the punch, and the rubber exhibited higher concentration of the compressive strain than foams. Two-dimensional curved surface was formed successfully by the multi-point elasto-dieless forming method using an optimal combination of rubber and foam materials.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.08a
• /
• pp.21-28
• /
• 2003

Recently, instead of a matched die forming method requiring a high cost and long deliverly ten a multi-point dieless forming method using a pair of matrix type punch array as flexible dies has been developed. As this multi-point dieless forming method has some disadvantage of difficulty in precise punch control and high-cost of equipment, a new concept of multi-point dieless forming method combined with elastomer forming was suggested in this study. For optimal selection of elastomers, compression tests of rubbers, polyethylene and foams were carried out together with FEM analysis of the deformation behavior during sheet forming process using a rigid punch and elastomers. Compressive strain was concentrated on the upper central area of the elastomer under the punch, and the rubber exhibited higher concentration of the compressive strain than foams. Two-dimensional curved surface was formed successfully by the multi-point elasto-dieless forming method using an optimal combination of a rubber and foam.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.17 no.5
• /
• pp.45-51
• /
• 2018

Roll forming refers to the production of long plate-molded products, such as panels, pipes, tubes, channels, and frames, by continuously causing the bending deformation to thin plates using rotating rolls. As the roll forming method has advantages in terms of mass production because of its excellent productivity, the size of the roll forming industry has been continuously increasing and the roll forming method is increasingly being used in diverse industrial fields as a very important processing method. Furthermore, as the roll forming method mainly depends on the continuous bending deformation of the plate materials, the time and the cost of the heterogeneous materials developed in the process are relatively large when considered from the viewpoint of plastic working because many processes are continuously implemented. The existing studies on roll forming manufacturing have reported the loss of large amounts of time and materials when the raw materials or product types were changed; further, they have stated that the use of this method can hardly guarantee the uniformity of the formed shapes and the consistency in terms of size and cannot detect all the defects occurring during the mass production and related to the dimensions. Therefore, in this research, a real-time process data-based smart roll forming method that can be applied to multiple products was studied. As a result, a roll forming system was implemented that remembers and automatically sets the changes in the finely adjusted values of the supplied quantities of individual heterogeneous materials so that the equipment setting changing time for heterogeneous material replacements or changes in the products being produced can be shortened. It also secures the uniformity of the products so that more competitive and precise slide-rail products can be mass-produced with improvements in the quality, price, and productivity of the products.

• Journal of the Korean Society of Marine Environment & Safety
• /
• v.24 no.3
• /
• pp.360-366
• /
• 2018

In shipyards hull forming is performed by the line heating method using a gas torch and by cold treatment using a roll-press. However, this forming process has some issues, such as difficulties in controlling and accurately estimating the amount of the heat input, as well as a harsh working environment due to exposure to loud noises and air pollution. The induction heating method, which is introduced in this paper, exhibits good control and allows for the estimation of precise heat input. Also, workers can carry out the induction heating in a comfortable working environment. In this research, the induction heating simulation, which consists of electro-magnetic, heat transfer and thermal elasto-plastic analysis, was developed and modified through induction heating experiments. Finally, the effective heating coil was designed for the automatic hull forming system based on the results of induction heating simulation. For the purposes of a future study, if an algorithm to obtain optimal working conditions is developed, automatic systems for hull forming can then be constructed.

• Transactions of Materials Processing
• /
• v.33 no.1
• /
• pp.43-49
• /
• 2024

A high strength steel sheet (HSSS) has widely used to improve the specific rigidity of parts and the safety of the passenger in automotive industries. However, the HSSS is difficult to manufacture precise parts through a forming process due to the reduced elongation and the increased elastic recovery. The goal of the paper is to investigate the improved design of bending dies for DP590 HSSS. The over forming type bending dies with cam systems added to the side of the formed part is proposed to improve the quality of the part. The effects of the die design and the forming parameter on formability and elastic recovery characteristics is examined using finite element analyses (FEAs). From the results of FEAs, proper die design and forming parameters are predicted.