• Transactions of Materials Processing
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• v.5 no.4
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• pp.281-287
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• 1996

Two kinds of blank shapes optimum and square are adopted to investigate formability. Optimum blank shape is determined to construct an L-shape cup with uniform height and without flange part. For this purpose rigid-plastic FEM analysis is applied with backward tracing technique. Maximum cup depth and strain distribution are measured experimentally for the products of the two kinds of blank shapes which are optimum and square. it is confirmed that deeper cup without severe thickness reduction can be obtained from the optimum shape.

• Transactions of Materials Processing
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• v.5 no.2
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• pp.138-144
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• 1996

The differences of formability with maximum cup depth of drawn product and thickness strain distribution are compared for two kinds of blank shapes which are suggested optimum shape and conventional square shape. The suggested blank is determined by backward tracing technique of rigid-plastic FEM. The deeper cup without wrinkle and flange part could be obtained from the suggested blank shape however the cross sevtion sup from the square blank could not be kept smooth thickness strain distribution and defended those phenomena..

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.2
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• pp.450-455
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• 2017

A shield connector is an automotive electrical component that is used to connect electrical wiring in a vehicle. This part is made by progressive pressing using a phosphor bronze material with high electrical conductivity. The shape of the product is not complicated, but plastic forming techniques are required, such as deep drawing and bending, as well as shearing techniques such as piercing and notching. The finite element method was used to model the process. The strip layout design stage of the progressive die makes it possible to examine the thickness change, the stability of the forming process, and the spring-back. As a result of this analysis, it is possible to predict the correction values for the tendency of cracks, wrinkles, and incomplete plastic deformation, and to identify possible problems in advance. As a countermeasure against the forming error caused by the drawing process analysis, the drawing shape was modified and applied in the process design. For effective material utilization, a 3D strip layout was designed using an optimized blank shape based on nesting. The results improve the crack stability and spring-back of shield connector products produced through progressive pressing.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.9
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• pp.186-191
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• 2001

Spinning process is a chipless metal forming method for axi-symmetric parts, which is more economical, efficient and versatile method for producing parts than the other sheet metal forming process such as stamping or deep drawing. In this study, a fundamental experiment was conducted to improve productivity with process parameters such as tool path, angle of roller holder($\alpha$), feed rate($\gamma$) and corner radius of forming roller(Rr). These factors were selected as variables in the experiment because they were most likely expected to hale an effect on spring back. The empirical results were analyzed to know how much spring back was affected by these factors. And also thickness and diameter distribution of a multistage cup obtained by spinning process were observed and compared with those of a commercial product produced by conventional deep drawing.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.6 no.3
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• pp.26-35
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• 1997

In this study, the drawing characteristics of circular drawbead are examined with the plane strain elastic-plastic FE Method. Both the clamping load and the drawing load investigated by varying the process variables such as drawbead radius, closing depth and friction condition. The effective strain induced by the draw bead is also investigated. In order to verify the results, the computed results are compared with the existing experimental results. It has been found that both the clamping load and drawing loads are related with the geometry of the bead rather than the lubrication conditions.

• Transactions of Materials Processing
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• v.24 no.5
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• pp.323-331
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• 2015

Impact extrusion is an economical and productive process that can replace the multistage deep drawing process for producing deep rectangular cases. In the current work, a three-dimensional finite element analysis of the impact extrusion process of a commercial purity aluminum alloy (AA1070) was performed to predict loads, material flow, and deformed shapes using the Hansel-Spittel rheology law, which describes the flow stress at various temperatures and strain rates. The role of various process parameters such as friction, clearance between punch and die, aspect ratio and thickness of billet on the process and the shapes was analyzed.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.10
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• pp.696-701
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• 2016

Multi-stage deep drawing is a widely used industrial manufacturing process, and its applications are gradually expanding to both small products and large metallic products. The USB C-type socket used in smart phones, for example, is manufactured using oval multi-stage deep drawing. The socket is very small and slender and it requires precise manufacturing. The thickness distribution of the final product is guaranteed only if it is uniform throughout the overall process. Therefore, minimizing the height difference between long and short sidewalls after the first operation is important for this goal. An initial blank optimization was performed for an oval-type drawing process based on finite element simulations. The goal was to determine an initial blank geometry that can maintain uniform height and thickness after the first draw operation. The initial blank shape of the sheet metal was optimized, and the results show that it satisfied the conditions of minimal thickness reduction and even thickness distribution. The geometry from the optimized simulation was compared with experimental results, which showed good agreement.

• Transactions of Materials Processing
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• v.15 no.3 s.84
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• pp.232-240
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• 2006

Magnesium alloys are expected to be widely used fur the parts of structural and electronic appliances due to their lightweight and EMI shielding characteristics. While the die casting has been mainly used to manufacture the parts from the magnesium alloys, the press forming is considered as an alternative to the die casting for saving the manufacturing cost and improving the structural strength of the magnesium alloy parts. However, the magnesium alloy has low formability at room temperature and therefore, in many cases, forming at elevated temperatures is necessary to obtain the required material flow without failure. In the present study, square cup deep drawing tests using the magnesium alloy AZ31 sheet were experimentally conducted at various elevated temperatures as well as room temperature, and the corresponding finite-element simulations, which calculated the damage evolution based on the Oyane's criterion, were conducted using the stress-strain relations from the tensile tests at various temperatures. The formability predictability by the finite-element analysis was investigated by comparing the predicted damage distributions over the deformed AZ31 sheet at elevated temperatures with the corresponding experimental deformations with failures.

• Transactions of Materials Processing
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• v.29 no.5
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• pp.272-281
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• 2020

As the thickness of mobile communication devices is getting thinner, the size of the internal parts is also getting smaller. Among them, the battery case requires a high-level deep drawing technique because it has a rectangular shape with a large aspect ratio. In this study, the initial blank shape was optimized to minimize earing in a multi-stage deep drawing process using an artificial neural network(ANN). There has been no reported case of applying artificial neural network technology to the initial blank optimal design for a square case with large aspect ratio. The training data for ANN were obtained though simulation, and the model reliability was verified by performing comparative study with regression model using random sample test and goodness-of-fit test. Finally, the optimal design of the initial blank shape was performed through the verified ANN model.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.9
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• pp.302-307
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• 2016

The technology of multistage deep drawing has been widely applied in the metal forming industry, in order to reduce both the manufacturing cost and time. A battery can used for mobile phone production is a well-known example of multistage deep drawing. It is very difficult to manufacture a battery can, however, because of its large thickness to height aspect ratio. Furthermore, the production of the final parts may result in assembly failure due to springback after multistage deep drawing. In industry, empirical methods such as over bending, corner setting and ironing have been used to reduce springback. In this study, a bottoming approach using the finite element method is proposed as a practical and scientific method of reducing springback. Bottoming induces compression stress in the deformed blank at the final stroke of the punch and, thus, has the effect of reducing springback. Different cases of the bottoming process are studied using the finite element program, DYNAFORM, to determine the optimal die design. The results of the springback simulation after bottoming were found to be in good agreement with the experimental results. In conclusion, the proposed bottoming method is expected to be widely used as a practical method of reducing springback in industry.