• 제목/요약/키워드: Sheet-Metal Forming Process

검색결과 428건 처리시간 0.022초

점진성형에서 알루미늄 판재의 성형성에 대한 연구 (A Study on Formability of Aluminum Sheet in Incremental Forming)

  • 박종진;김영호
    • 대한기계학회:학술대회논문집
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    • 대한기계학회 2003년도 춘계학술대회
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    • pp.1142-1147
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    • 2003
  • The formability of sheet metal appears better in incremental forming than in conventional forming. in this study, the effect of process parameters - tool type, tool size, feed rate, friction at the interface between tool and sheet, plane-anisotropy of sheet - on the formability was investigated by experiments and FEM analyses. it was found that the formability is improved when a ball tool of a particular size is used with a small feed rate and a little friction. Due to the plane anisotropy, the formability differs according to the direction of the tool movement. in this paper, details of the experimental procedures and the results obtained from the study are discussed.

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강소성 유한요소법과 반응표면분석법을 이용한 박판성헝 공정에서의 비드력 및 다이형상의 설계 (Design of the Bead Force and Die Shape in Sheet Metal Forming Processes Using a Rigid-plastic Finite Element Method and Response Surface Methodology)

  • 김세호;허훈
    • 소성∙가공
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    • 제9권3호
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    • pp.284-292
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    • 2000
  • Optimization of the process parameters is carried out for process design in sheet metal forming processes. The scheme incorporates with a rigid-plastic finite element method for the deformation analysis and response surface methodology for the optimum searching of process parameters. The algorithm developed is applied to design of the draw bead force and the die radius in deep drawing processes of rectangular cups. The present algorithm shows the capability of designing process parameters which enable the prevention of the weak part of fracture during processes.

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유한요소해석을 이용한 차체시작부품 프레스성형 공정 개선 (Improvement of the Stamping Process for Sheet Metal Prototypes of an Auto-body with Finite Element Analysis)

  • 김세호
    • 한국정밀공학회지
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    • 제28권4호
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    • pp.496-504
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    • 2011
  • This paper introduces a CAE-based design procedure in the press forming process for the fabrication of sheet metal parts used in proto-cars. The finite element analysis reveals formability problems during the forming process of a floor member and a front cross member that constitute a rear floor assembly. The study proposes the modification of the initial blank shape or intermediate trimming of the product to prevent failure during forming. It is confirmed by the tryout process as well as the finite element analysis that sound prototype can be obtained with the modified design. The finite element analysis result also provides fairly good prediction of springback amounts used for the post-compensation of the product.

박판 성형공정에서의 등가 경계조건 계산을 위한 드로우비드 성형의 탄소성 유한요소 해석 - Part II : 프런트 도어 판넬 성형공정에서의 적용 (Elastic-plastic Finite Element Analysis of Drawbead Forming for Evaluation of Equivalent Boundary Conditions in Sheet Metal Forming - Part II : Application to the front Door Panel Forming Process)

  • 박종세;김승호;허훈
    • 소성∙가공
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    • 제11권6호
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    • pp.513-518
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    • 2002
  • The equivalent boundary conditions have been applied to the front door panel forming process, in order to demonstrate its reliability and validity. The elongation in the bead forming process is applied to the binder wrap process as the equivalent displacement boundary condition and the restraining force in the drawing process is applied to stamping process as the equivalent force boundary condition. The result calculated with the equivalent boundary conditions shows closer coincidence with the experimental result than simulation with different boundary conditions. The numerical result fully demonstrates that drawbead forming simulation for calculation of equivalent boundary conditions is necessary and effective.

쉘 요소를 이용한 박판성형공정의 유한요소해석 (Finite Element Analysis of Sheet Metal Forming Process Using Shell Element)

  • 정동원;고형훈;이찬호;유호영
    • 한국정밀공학회지
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    • 제23권1호
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    • pp.152-158
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    • 2006
  • 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 is well-known that the membrane analysis can not provide correct information for the processes which have considerable bending effects. In this research experimental results were compared with the analysis results obtained by using the shell element which is applied newly in the AutoForm commercial software. The shell element is a 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.

판재 성형을 위한 마찰 계수에 관한 연구 (A Study on Friction Coefficient for Sheet Metal Forming)

  • 박동환;강성수
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 2001년도 춘계학술대회 논문집
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    • pp.28-31
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    • 2001
  • Friction for sheet metal forming affects improvement of deep drawing formability. The deep drawing is affected by many process variables, such as lubricant, blank shapes, shape radius and so on. Especially, lubrication is very important formability factor. In this study, in order to investigate fraction coefficient of sheet metal forming, we examined friction test about three conditions, such as non-lubrication, full lubrication and film lubrication. We measured friction coefficient according to pin load under the conditions like deep drawing die. Mean friction coefficient for film lubrication condition would be very useful value to improve drawability.

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리어 힌지 패널 스템핑의 유한요소해석 (Finite Element Analysis of Auto-body Panel Stamping)

  • 정동원;이장희;양동열
    • 한국소성가공학회:학술대회논문집
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    • 한국소성가공학회 1996년도 자동차부품 제작기술의 진보
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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.

중첩된 박판간의 결합을 위한 접착-성형공정 (Form-Joining Process with the Aid of Adhesive for Joining of Sheet Metal Pair)

  • 정창균;김태정;양동열
    • 소성∙가공
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    • 제13권4호
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    • pp.342-349
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    • 2004
  • The form-joining process (or clinching) uses a set of die and punch to impose the plastic deformation-induced geometric constraint on a sheet metal pair. The joining strength from the process ranges 50-70 percent of that of the resistance spot welding. In this paper, a new form-joining process with the aid of an adhesive is proposed in which an epoxy adhesive is applied to a sheet metal pair, and before it cures the pair is clinched to cause the geometric constraint in the form of a protrusion. In order to reduce the forming load and the height of protrusions, a new die and punch set with a very small clearance is devised to reduce the depth of drawing and the forming load. Taguchi method is employed to find the optimal values of design parameters. To implement each case of the orthogonal array, the finite element method is used. The experiments show that in the tensile-shear test, the bonding strength of the new form-joining process with an epoxy adhesive is approximately the same as that of the resistance spot welding; and in comparison with the other two form-joining processes with an epoxy adhesive, the height of protrusions is reduced by more than 65 percent and the forming load by 50 percent.

알루미늄 판재의 다단계 드로잉에 있어서 원통컵의 치수 정밀도 비교 (Dimensional Accuracy of Cylindrical Cups in Multi-Stage Drawing of Aluminum Sheet Metal)

  • 최종민;김종호
    • 소성∙가공
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    • 제24권2호
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    • pp.115-120
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    • 2015
  • Deep drawing of cylindrical cups is one of the most fundamental and important processes in sheet metal forming. Circular cups are widely used in industrial fields such as automobile and electronic appliances. Some of these cups are formed by a one-stage process, others such as battery cases and beverage cans are made by a multi-stage process. In the current study the multi-stage deep drawing of aluminum sheet metal is examined. The process consists of two deep drawing operations followed by two ironing operations. The press die, which can be used for the four-stage forming process, was manufactured allowing punch and die components to be easily changed for various experiments. The rolling direction of both the sheet and the drawn cups was always positioned toward the horizontal x-direction on the die face to minimize experimental errors during the progressive forming. The dimensional accuracy of the cylindrical cups formed at each stage and the earing defect due to the anisotropy of sheet were investigated. The influence of anisotropy on the thickness distribution was also examined. Both the thickness and the outer diameter of the cups were measured and compared for each set of experimental conditions. It was found that the dimensional accuracy of cups rapidly improves by employing the ironing process and also by increasing the amount of ironing.

유한요소해석을 이용한 마이크로 박판 미세 패턴 롤-롤 성형공정 설계 (Design of Roll-to-Roll Forming Process for Micro Pattern on the Thin Sheet Metal by Finite Element Analysis)

  • 차성훈;신명수;이혜진;김종봉
    • 소성∙가공
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    • 제19권3호
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    • pp.167-172
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    • 2010
  • Roll-to-roll forming process is one of important metal processing technology because the process is simple and economical. These days, with these merits, roll-to-roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate. However, it is difficult to apply to the forming of micro scale or sub-micro scale pattern. In this study, the roll forming processing for the micro scale is designed and analyzed. The forming of micro pattern for small electric device such as LCD panel by incremental roll forming process is analyzed. Firstly, the optimum analysis conditions are found by several analyses. And then, formability is analyzed for various protrusion shapes at various forming temperatures. The formability is evaluated in terms of filling ratio and damage value. The filling ratio is defined from the tool geometry and critical damage is determined from the analysis of uniaxial tensile test. Finally, optimum forming conditions that guarantee the successful forming are found.