• Transactions of Materials Processing
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• v.31 no.2
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• pp.57-63
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• 2022

The current study performed formability analysis of a heat exchanger separator for an electric vehicle to apply a high-strength aluminum sheet based on parametric analysis. Mechanical properties for sheet metal forming simulation were evaluated by tensile test, bulge test, and Nakajima test. Two-stage crash forming was established by considering the mass production process using conventional low-strength aluminum sheets. In this study, FEM for the two-stage forming process was conducted to optimize the corner radius and height for improving the formability. In addition, the possibility of a one-stage forming process application was confirmed through FEM. The prototype of the sample was manufactured as FEM results to validate the parametric analysis. Finally, this result can provide a one-stage forming process design method using the high-strength aluminum sheet for weight reduction of a heat exchanger separator for an electric vehicle.

• Design & Manufacturing
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• v.14 no.2
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• pp.49-55
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• 2020

Recently, when a new component of construction equipment is designed, a stamping process capable of producing parts having high appearance quality and precision has been gaining attention. However, in general, as it is developed based on existing parts made by welding metal sheets and tubes, frequent to die modification occurs, which increases the time and cost of developing new parts. Thus, it is necessary to reduce the cost by shortening the die development period. In this study, a stamping process was designed for the urea tank cover, which is a part for excavators, to reduce the die development period through sheet metal forming analysis. The stamping process was designed by determining the blank holding force after selecting the initial blank shape and size. The round value at the corner was modified such that formability is ensured. After selecting process parameters, the thickness reduction rate and spring-back effect were reviewed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.06a
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• pp.1-9
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• 1994

Three recent developments made at Rensselaer in sheet material forming processes are briefly reviewed in this paper. These advances represent three broad disciplines of Process Simulation, Forming Processes, and Computer-Aided Measurement Methods. The first development deals with simple and quick computer simulation of 2D sheet forming process without depending on popular finite element analysis methods. An analytical method based on a thin shell theory accounts for bending and unbending effects, and is capable of simulating practical sheet metal forming processes under the plane strain condition. The second area is concerned with innovative methods to improve formability of sheet materials by temperature gradient forming. The drawing limit is increased by such an improved temperature gradient forming process. The third and final area deals with a totally new experimental technique to capture 3D geometry data and measure strain distributions of sheet metal parts using a digital 35mm SLR camera.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.643-648
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• 2008

Ultra-thin sheet metal forming techniques are required in precision forming of miniaturized and integrated products. In order to manufacture a good quality and low cost ultra-thin sheet metal products, a highly precise high-speed press is needed. The precision of a press is related with its vibration characteristics during pressing operation. This study evaluated the vibration characteristics of a proposed press design using computer simulation. The analysis compares the static deformation characteristics of the slide and the slide motion for the metal forming of an ultra-thin sheet of thickness less than 0.1mm. Further, in order to minimize the vibrations during high speed pressing operation, revolution balances of the eccentric shaft and the balance weight device is also considered. Finally, modal analysis is used to characterize the natural frequency of vibration of the press.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.10
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• pp.890-896
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• 2008

Sheet metal forming is one of the most useful and important method in manufacturing of the autobody panels because of the excellent production rate. The objectives of sheet metal forming processes are getting a desired geometrical shape of products with good quality, low cost and reasonable lead time. In this paper, we examined the validity of finite element method analysis on the automobile FRT-PLR-L/R stamping process by using the lancing engineering method. Lancing is a press operation in which a single-line cut or slit is made on part way across the strip stock, without removing any metal. As a result, it has shown that the proper lancing engineering method could prevent fracturing by improving sheet metal flow.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.06a
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• pp.97-109
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• 1996

In the present work computations are carried out for analysis of complicated sheet metal forming process such as forming of a rear hinge. Finite element formulation using dynamic explicit time integration scheme and step-wise combined Implicit/Explicit scheme are introduced for numerical analysis of sheet metal forming process. The rigid-plastic finite element method based on membrane elements has long been employed as a useful numerical technique for the analysis of sheet metal forming because of its time effectiveness. The explicit scheme in general use is based on the elastic-plastic modelling of material requiring large computation time. In finite element simulation of sheet metal forming processes, the robustness and stability of computation are important requirements since the computation time and convergency become major points of consideration besides the solution accuracy due to the complexity of geometry and boundary conditions. The implicit scheme employs a more reliable and rigorous scheme in considering the equilibrium at each step of deformation, while in the explicit scheme the problem of convergency is eliminated at the cost of solution accuracy. The explicit approach and the implicit approach have merits and demerits, respectively. In order to combine the merits of these two methods a step-wise combined implicit/explicit scheme has been developed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.6 s.177
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• pp.1624-1632
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• 2000

In the sheet metal forming process, the drawbead is used to control the flow of material during the forming process. The drawbead provides proper restraining force to the material and prevents defe cts such as wrinkling or breakage. For these reasons, many studies for designing the effective drawbead have been conducted. In this paper, the effect of the drawbead shape will be introduced. For the analysis, the numerical method called the static-explicit finite element method was used. The finite element analysis code for this method has been developed and applied to the drawbead process problems. In result, convergence problem and computation time due to large non-linearity in the existing numerical analysis methods were no longer a critical problem. Futhermore, this approach could treat the contact friction problem easily by applying very small time intervals. It is expected that various results from the numerical analysis will give very useful information for the design of tools in sheet metal forming process.

• Transactions of Materials Processing
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• v.7 no.3
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• pp.233-245
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• 1998

A new approach has been proposed for the incremental analysis of the nonsteady state large deformation of planar anisotropic elastic-plastic sheet forming. A mathematical brief review of a constitutive law for the incremental deformation theory has been presented from flow theory using the minimum plastic work path for elastic-plastic material. Since the material embedded coordinate system(Lagrangian quantity) is used in the proposed theory the stress integration procedure is completely objective. A new return mapping algorithm has been also developed from the general midpoint rule so as to achieve numerically large strain increment by successive control of yield function residuals. Some numerical tests for the return mapping algorithm were performed using Barlat's six component anisotropic stress potential. Performance of the proposed algorithm was shown to be good and stable for a large strain increment, For planar anisotropic sheet forming updating algorithm of planar anisotropic axes has been newly proposed. In order to show the effectiveness and validity of the present formulation earing simulation for a cylindrical cup drawing and front fender stamping analysis are performed. From the results it has been shown that the present formulation can provide a good basis for analysis for analysis of elastic-plastic sheet metal forming processes.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.481-484
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• 2005

The AutoForm previously used the membrane element and it accomplished sheet metal forming analysis. The membrane analysis has been widely applied to various sheet metal forming processes because of its time effectiveness. However, it's well known that the membrane analysis can not provide correct information for the processes which have considerable bending effects. In this research it tried to compare the analysis results which use the shell element which is applied newly in the AutoForm commercial software with actual experimental results. The shell element is compromise element between continuum element and membrane element. The Finite element method by using shell element is the most efficient numerical method. From this research, it is known that FEA by using shell element can predict accurately the problems happened in actual experimental auto-body panel.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.10a
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• pp.206-211
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• 1993

The explicit scheme for finite element analysis of sheet metal forming problems has been widely used for providing practical solution since it improves the convergency problem,memory size and computational time especially for the case of complicated geometry and large element number. In the present work, a basic formulation for rigid-plastic explicit finite element analysis of plain strain sheet metal forming problems has been proposed. The effect of some basic parameters involved in the dynamic analysis has been studied in detail. A direct trial-and-error method is introduced to treat contact and friction. In order to show the validity and effectiveness of the proposed explicit scheme, computation are carried out for cylindrical punch stretching and the computational results are compared with those by the implicit scheme as well as with a commercial code. The proposed rigid-plastic explicit element method can be used as a robust and efficient computational method for analysis of sheet method forming.