• Transactions of Materials Processing
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• v.14 no.4 s.76
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• pp.392-398
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• 2005

The deterioration of dimensional accuracy, caused by springback, is one of problems to always occur In sheet metal forming processes. As the demand for lighter and stronger metals increases, the development of improved forming processes settling the springback problem becomes more important. In this work, asymmetric springback phenomena are investigated, which occur in the shallow-drawing process with the anisotropic sheet metal and axisymmetric tools. The improvement possibility of dimensional accuracies, mainly, flatness, was examined by applying segmented blank holding forces as a method for springback control.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.389-392
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• 2003

The deterioration of dimensional accuracy, caused by springback, is one of problems to always occur in sheet metal forming processes. As the demand for lighter and stronger metals increases, the development of improved forming processes settling the springback problem becomes more important. In this work, springback phenomena are investigated which occur in the press forming process with the anisotropic sheet metal and axisymmetric tools. The improvement possibility of dimensional accuracies, mainly, flatness, will be examined by applying blank holding forces as a method of springback control.

• Design & Manufacturing
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• v.12 no.2
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• pp.40-45
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• 2018

Recently, in construction equipment machinery production, development has focused on environmentally-friendly functions to improve existing production capacity. For excavators as well, emphasis has been placed on response to environmental regulations, miniaturization, and noise reduction, while technology is being developed considering cost reduction and safety.Accordingly, the front support, an inner reinforcement part of the excavator, as well as high-strength steel plates to improve safety and reduce weight, are being applied.However, in the case of high-strength materials, Springback occurs in the final formed part due to high residual stress during product forming. Derivation of a forming or product shaping process to reduce springback is needed. Accordingly, regarding the front support, an inner reinforcement part of the excavator, this study derived a method to improve springback and secure shape stiffness through analysis of the springback occurrence rate and springback causes through a forming analysis.As for the results of analyzing the springback occurrence rate of existing products through forming analysis, springback of -22.6 mm < z < 27.35 mm occurred on the z-axis, and it was confirmed that springback occurred due to the stiffness reinforcing bead of the upper and middle parts of the product.To control product residual stress and springback, we confirmed a tendency of springback reduction through local pre-cutting and stiffness reinforcement bead relocation.In the local pre-cutting model, springback was slightly reduced by 5.3% compared with the existing model, an insignificant reduction effect. In the stiffness reinforcement bead relocation model, when an X-shaped stiffness reinforcement bead was added to each corner portion of the product, springback was reduced by at least 80%.The X-shaped bead addition model was selected as the springback reduction model, and the level of stiffness compared to the existing model was confirmed through a structural analysis.The X-shaped bead additional model showed a stress springback of 90% and springback reduction of 7.4% compared with the existing model, indicating that springback and stiffness will be reinforced.

• Transactions of Materials Processing
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• v.18 no.3
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• pp.210-216
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• 2009

Springback, an elastic material recovery after the unloading of stamping tools, causes variations and inconsistencies of final part dimensions. Recently, narrow and long surround molding parts around door frame are applied to high grade automobiles, but there are great difficulties in their die development, construction and tryout because of several springback modes including vertical movement and twist during flange forming process of them. So it is very important to predict springback's quantities of a surround molding part and, moreover, to compensate the die for them adequately, when they can't be corrected by the restrike operation. This paper presents a case study based on the die design for a surround molding part made of stainless steel. The forming and springback predictions, carried out using PAMSTAMP 2G, are reported and compared with the measurement data of the prototype. The predicted springback results were acceptable, so the processes of compensating die using Automatic Die Compensation Module of PAMSTAMP 2G were performed iteratively until the tolerances between the designed shape and the simulation data were satisfied.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.301-306
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• 2009

High strength steels are widely used for lightweight automobile parts and the control of springback is very important in sheet metal forming. The object of this study is to develop the forming process for stair type side sill made of high strength steel, DP780. Stair type side sill with local formed area and geometry change area can improve stiffness and design freedom but there are a few studies for forming process. The forming technology considered in this paper is form type process, which have many advantages for farming of high strength steel compared with draw type process. Finite element analysis is carried out to predict formability and springback. It is shown that angle calibration of die is essential for reducing springback, and local forming involving bead is effective to control springback also. The effectiveness of local forming and angle calibration is verified by experimental.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.601-606
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• 2009

High strength steels are widely used for lightweight automobile parts and the control of springback is very important in sheet metal forming. The object of this study is to develop the forming process for stair type side sill made of high strength steel, DP780. Stair type side sill with local formed area and geometry change area can improve stiffness and design freedom but there are few studies for forming process. The forming technology considered in this paper is form type process, which has many advantages for forming of high strength steel compared with draw type process. Finite element analysis is carried out to predict formability and springback. It is shown that angle calibration of die is essential for reducing springback, and local forming involving bead is effective to control springback also. The effectiveness of local forming and angle calibration is verified by experimental.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.75-80
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• 2001

The purpose of this study is to investigate the characteristics of springback for various process conditions of the 2D draw-bending operation. The process variables are the forming temperature, the geometry of tools such as punch profile radius(Rp) and die profile radius(Rd). Especially, in order to control the springback, the use of the warm forming method is applied. For the warm draw-bending, five steps of temperature ranges, from room temperature to $200^{\circ}C$, were adopted. And two kinds of steel sheets, namely SCP1 and TRIP(transformation-induced plasticity), the newly developed high strength Steel, were adopted. As a result, the springback was affected by the elevated temperature and the geometry of tools in two kinds of steel sheets.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.47-52
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• 2004

Springback comes from the release of residual stress after forming. The control of phenomenon is especially important in the sheet metal forming since there are no other practical methods available to correct the dimensional inaccuracy from springback. Therefore the accurate predication before the die machining has been a long goal in the Held of sheet metal forming. The aim of the present study is to enhance the prediction capability of finite element(FE) analysis for the springback phenomenon. For this purpose FE analysis for V-bending has been carried out with the commercial programs, LS-DYNA. The FE analysis results have been validated through the comparison of experimental. The experimental results measured directly by the strain gauge have given the confidence to FEA.

• Transactions of Materials Processing
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• v.17 no.3
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• pp.197-202
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• 2008

The control of springback is very important in sheet metal forming since springback affects the dimensional inaccuracy of product. The object of this study is to design the manufacturing process for the improvement of the performance of seat rail by DP780. The influence of process variables such as bend angle and pad force on the springback has been firstly investigated through the comparison between the results of FE-analysis and trial out for initial design based on designer's experience. The process variables of the initial design have been modified in order to improve the dimensional accuracy of seat rail from the prediction of springback by FE-analysis. It was shown from experiment that the improved design satisfied the required specifications such as the dimensional accuracy and the strength of seat rail.

• Transactions of Materials Processing
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• v.13 no.6 s.70
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• pp.490-496
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• 2004

Springback comes from the release of external loads after forming. The control of phenomenon is especially important in the sheet metal forming since there are no other practical methods available to correct the dimensional inaccuracy from springback. Therefore the accurate prediction before the die machining has been a long goal in the field of sheet metal forming. The am of the present study is to enhance the prediction capability of finite element (FE) analysis for the springback phenomenon. For this purpose FE analysis for V-bending has been carried out with the commercial programs, LS-DYNA. The FE analysis results have been validated through the comparison of experimental. The experimental results measured directly by the strain gauge have given the confidence to FEA.