• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.63-70
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• 2016

Deep drawing is a forming process in which a blank of sheet metal is radially drawn into a forming die by the mechanical action of a punch and converted to required shape. Deep drawing involves complex material flow conditions and force distributions. Radial drawing stresses and tangential compressive stresses are induced in flange region due to the material retention property. These compressive stresses result in wrinkling phenomenon in flange region. Normally blank holder is applied for restricting wrinkles. Tensile stresses in radial direction initiate thinning in the wall region of cup. The thinning results into cracking or fracture. The finite element method is widely applied worldwide to simulate the deep drawing process. For real-life simulations of deep drawing process an accurate numerical model, as well as an accurate description of material behavior and contact conditions, is necessary. The finite element method is a powerful tool to predict material thinning deformations before prototypes are made. The proposed innovative methodology combines two techniques for prediction and optimization of thinning in automotive sealing cover. Taguchi design of experiments and analysis of variance has been applied to analyze the influencing process parameters on Thinning. Mathematical relations have been developed to correlate input process parameters and Thinning. Optimization problem has been formulated for thinning and Genetic Algorithm has been applied for optimization. Experimental validation of results proves the applicability of newly proposed approach. The optimized component when manufactured is observed to be safe, no thinning or fracture is observed.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.6
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• pp.87-93
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• 2004

An experimental is carried out to investigate the characteristics of blanking for nickel alloy Alloy42 (t=0.203mm), a kind of IC lead frame material. By varying clearance between die and punch the shapes of shear profile are examined. Finite element analysis with element deletion algorithm for ductile fracture mode is also carried out to study the effect of clearance theoretically and to compare with experimental results. The rectangular shape specimen with four different comer radius is used to study the characteristics of blanking for straight side and comer region simultaneously. As the result the ratios measured k(m experiment of roll over, burnish and fracture zone based on initial blank thickness are compared with those of FE analysis. Both experiment and FE analysis show that the amount of mil over and fracture is increased as the clearance increases. When the radius of comer is less than thickness of blank it has been found that larger clearance is required than that of straight region in order to maintain same quality of shear profile at the comer region.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.3
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• pp.182-188
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• 2001

An experiment is carried out to investigate the characteristics of blanking for copper alloy C194 (t=0.254mm), a kind of IC lead frame material. By varying clearance between die and punch, the shapes of shear profile are examined. Finite element analysis with element deletion algorithm for ductile fracture mode is also carried out to study the effect of clearance theoretically and to compare with experimental results. The rectangular shape specimen with four different corner radius is used to study the characteristics of blanking for straight side and corner region simultaneously. As the result, the ratios measured from the experiment of roll over, burnish, and fracture zone based on intial blank thickness are compared with those of FE analysis. Both experiment and FE analysis show that the amount of roll over and fracture is increased as the clearance increases. It has been found that larger clearance is required than that of straight region when the radius of corner is less than thickness of blank, in order to maintain same quality of shear profile at the corner region.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.2
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• pp.84-90
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• 2003

Magnesium alloys have been paid attention In automotive and industries as lightweight materials, and with these materials it has been attempted at deep drawing process for assessment of formability of sheet metal. For warm deep drawing process with a local heating and cooling technique, both die and blank holder were heated at warm temperature while the punch was kept at room temperature by cooling water. Warm deep-drawing process with considering heat transfer was simulated by finite element method to investigate the improvement of deep-drawability and temperature distribution of Mg alloy sheet. The effect of sham rate sensitivity index on the deformation profile was considered in this work and the simulation results revealed that considering heat transfer is very effective for deep-drawability of Mg alloy. The deformed blank In considering heat transfer was drawn successfully without any localized thinning and the cup height is higher in contrast to results of simulations in considering no heat transfer.

• Transactions of Materials Processing
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• v.25 no.6
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• pp.379-389
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• 2016

As a stator for steam turbine diaphragm, hollow-type nozzle stator to substitute for conventional solid one is introduced in this study. This hollowed stator can be separated into two parts such as upper and lower plates with large and curved surface area. This study focuses on thick plate forming process for the upper plate of the hollow-partitioned nozzle stator. First, to reduce forming defects such as under-cut and localized thinning of the deformed plate, and to avoid tool interruption between forming punch and lower die, tool design including the position determination of forming surfaces is performed. Uni-axial tensile tests are carried out using SUS409L steel plate with initial thickness of 5.00mm, and plastic strain ratio (r-value) is also obtained. Due to the asymmetric curved configuration of the upper plate, it is hard to adopt a series of blank holder or draw-bead, so the initial plate during this thick plate forming experiences unstable and non-uniform contact. To easy this forming difficulty and find suitable tool geometry without sliding behavior of the workpiece in the die cavity, two geometric parameters with respect to each shoulder angle of the lower die and the upper punch are adopted. FE models with consideration of 21 combinations for the geometric parameters are built-up, and numerical simulations are performed. From the simulated and predicted results, it is shown that the geometric parameter combinations with ($30^{\circ}$, $90^{\circ}$) and ($45^{\circ}$, $90^{\circ}$) for the shoulder angle of the lower die and the upper punch are suitably applied to this upper plate forming of the hollow-partitioned nozzle stator used for the turbine diaphragm.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.2
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• pp.124-133
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• 1998

This paper describes a research work of developing a computer-aided design of blanking and piercing for irregular-shaped sheet metal products. An approach to the development of compact and practical CAB system is based on the knowledge-based rules. Knowledge for the CAD system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer. Based on knowledge-based rules, the system, STRT-DES, is designed by considering several factors, such as complexities of blank geometry and punch profile, availability of press equipment and standard parts, utilization ratio which minimizes the scrap in a single or a pairwise operation, bridge width, grain orientation and design requirements which maximize the strength of the part when subsequent bending is involved. This system checks a forming feasibility with both internal and external features, a dimension of blanked hole, and a corner and a fillet radius for irregualrly shaped sheet metal products. Therefore this system can carry out a die design for each process which is obtained from results of an automated blank layout drawing with a best utilization ratio for irregular shape of product that was successful in production feasibility check module and those of an automated strip layout drawing and generate part drawings and the assembly drawing of die set in graphic forms.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.281-284
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• 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.

• Journal of the Korean Society for Precision Engineering
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• v.5 no.3
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• pp.31-42
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• 1988

This paper describes a computer aided process planning system called "Deep-Drawing", "Deep-Drawing" is designed for the drawing sequence of cylindrical and rectangular cups with or without taper and flange. The computer program has written in BASIC language with personal computer. Design Rules for process planning are formulated from process limitation, plasticity theory and experimental results including the know-how of many manufacturing factories. "Deep-Drawing" Capabilities include the analysis of drawing sequence by the determination of optimal drawing ratio, the determination of intermediate shape, dimensions, punch and die radius etc., the calculation of drawing loads and blank holder force to perform each drawing step, and the graphic outputs for the operation sheet.tputs for the operation sheet.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1757-1760
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• 2005

This paper is concerned with spring back after sheet forming of bulk amorphous alloys in the super cooled liquid state. The temperature-dependence and strain-rate dependence of Newtonian/non-Newtonian viscosities as well as the stress overshoot/undershoot behavior of amorphous alloys are reflected in the thermo-mechanical Finite Element simulations. Hemispherical deep drawing operations are simulated for various forming conditions such as punch velocity, die corner radius, friction, blank holder force, clearance and initial forming temperature. Here, spring back by an instantaneous elastic unloading was followed by thermal deformation during cooling and two modes of spring backs are examined in detail. It could be concluded that the superior sheet formability of an amorphous alloy can be obtained by taking the proper forming conditions for loading/unloading.

• Journal of the Korean Society for Precision Engineering
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• v.7 no.3
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• pp.56-65
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• 1990

This paper describes a computer aided tool design system of deep drawing of cylindrical cups with or without flange by press. An approach to system is based on knowledge based system. The computer program has written in basic language with personal computer Knowledges for tool design are formulated from the plasticity theory, handbooks, experimental results and empirical knowhow of the field experts. The capabilities of developed system include 1) the selection of tool structure (with or without blank holder, single or double action, lift up or draw off type), 2) the design of tool elements(punch/holder, die/holder etc.) for the previous selected tool structure by the process planning output and the production quantity. The final output is generated in graphics form for design sheet.