• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.431-433
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• 2007

The drawbeads, which is used for controlling the flow of the sheet by imposing the tension and for preventing the springback in the sheet metal forming process, affects a lot the formability because of the differences in the restraint and opening forces according to the drawbead shapes and dimensions. In this study, the experimental device enabling to measure the drawbead restraining and opening forces was manufactured and the drawing forces of circular, square, and step drawbeads are measured. The drawbead restraining and opening forces of a circular drawbead are increased as its drawbead height is increased. Similarly, those of a square drawbead are increased as its height is increased and shoulder radii decreased. Also, those of a step drawbead are increased as its height and difference in their heights are increased.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.420-423
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• 2009

In this study, the guideline for designing the drawbeads used in the stamping dies for advanced high strength steel (AHSS) sheets is investigated. In the drawbead drawing test, the drawbead forces for verifying the equivalent drawbead model(EDM) and the sheet strains for finding marginal strains from $FLC_0$ are measured. In the finite element analysis (FEA), the bending allowance, R/t, is obtained. Based on the forming and bending allowances obtained, the design guideline of the drawbead for determining height and width, which depends on the restraining force and the forming allowance, is prepared by using EDM.

• Design & Manufacturing
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• v.6 no.1
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• pp.79-83
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• 2012

Anti-theft safety caps for bolted joints are necessary to ensure the safety of citizens and prevent theft of manholes, bridge guardrails, bulletin boards, subway safety handrails and others. Safety caps enhance the look of bolted joints, avert accidents that involve hitting the head of bolts, hamper them from coming loose by covering the head of bolts. This study focuses on press die design methods and press molding condition setting to resolve bursting and cracks in products, and on molding material selection and heat treatment technologies to boost life extension.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.194-197
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• 1997

The texture of a 0.25mm dia high-carbon(0.73%) steel wire made by drawing the patented and brass coated 1.4mm wire through 22 dies with a die-angle of 12$^{\circ}$has been measured. The ideal fiber texture was obtained in the center layer, while the circular texture and the near fiber texture having {111}<110> and weak {112}<110> components were obtained in the intermediate and surface layers, respectively. The circular texture was approximated by {110}<110> plus {110}<114>. The texture could be predicted by the Taylor-Bishop-Hill theory coupled with FEM for deformation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.326-329
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• 2005

Since the required strength of forged part is achieved by work hardening with the accumulation of plastic strain during the cold working, severe load can be exerted on die system. So, dies are liable to the early fracture for the non-heat treated steel forging in comparison with the conventional mild steels. Therefore, it is necessary to lower the flow stress of steels as much as possible during forging steps. Bauschinger effect can be utilized to lower flow stress during forging steps by giving the tensile prestrain on the forging billet during wire drawing step. In the present study, the prestrain effect on Bauschinger phenomenon is studied to avoid difficulties with application of non-heat treated cold forging steels in practice.

• Transactions of Materials Processing
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• v.9 no.1
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• pp.3-9
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• 2000

The new FLD of the laser welded blank, which includes FLCs of welded zone and base metals, is introduced. For the forming limits of welded zone, the hemispherical dome punch tests were performed with various widths of asymmetric specimen. The FLC0 as well as the dome height at fracture associated with various specimen widths in the same and different thickness combinations were found to see the formability depending on thickness combinations. In order to show the application of the new FLD, the measured strains of squared cup drawing and simulated strains of door inner panel stamping were compared with those of FLCs. The successful prediction of fracture in the applications reveals that the forming limits of welded zone and base metals should be separately found for more accurate evaluation of the formability and workability of the laser welded blank.

• Transactions of Materials Processing
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• v.7 no.6
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• pp.586-593
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• 1998

In recent automotive industries there has been significant increase in applications of computer simulation to the manufacturing of stamping dies for inner and outer body panels which greatly affect durability and aesthetic quality of automobiles. Enhancement of die quality and reduction of total die manufacturing time and consequently manufacturing cost are the visible outcome. However to successfully apply the result of simulation by a commercial package to the die manufacturing development of an optimal die manufacturing process is required upon the completion of analysis of forte and shortcoming of available sheet metal forming softwares. Based on the results of numerical analysis of front door outer panel forming. this paper evaluates the applicability of simulation results to the real die manufacturing for automotive body panels. Also it attempts to select an optimal die manufacturing process including design machining and tryout. Lastly it discusses the expected effects by adopt-ing the selected process in a real stamping die manufacturing facility.

• Transactions of Materials Processing
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• v.6 no.2
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• pp.152-160
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• 1997

Three-Dimensional finite element analysis is performed using PAM-STAMP for design evaluation of automotive back door inner panel die. Gravity process by blank own weigth, binder-wrap process, and drawing process in the forming operations are sequentially simulated with Virtual Manufacturing Method. The most valuable result in this research is that 3-D FEM analysis can be applied to the design evaluation of draw dies in the die try-out, though effects of mesh size and drawbead resistance force on the try-out, the experimental knowhows about the forming variables such as friction coefficient punch velocity, drawbead force, etc are necessary.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.3
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• pp.80-93
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• 1996

A 2-dimensional FEM/GEM program was developed under the plane strain assumption using linear line elements for analyzing stretch/draw forming operations of an arbitrarily shaped draw-die. FEM formulation adopted a new algorithm for solving force equilibrium as well as non-penetration condition simultaneously. Also, a rigid-viscoplastic material model with Hill's normal anisotropic yield condition and rate-sensitive hardening law is assumed, along with the Coulomb friction law in the contact regions. For the case of numerical divergence at nearly final forming stages, geometric force equilibrium method(GEM) is also introduced. The developed program was tested by simulating the forming processes of cylindrical punch/open die, and the drawing processes of automotive oilpan and hood inner panel in order to verify the usefulness and validity of FEM/GEM formulation. The numerical simulation verified the validity and robustness of developed program.

• Transactions of Materials Processing
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• v.27 no.4
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• pp.201-210
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• 2018

An airbag is an essential automotive component used in all kinds of vehicles such as an internal combustion engine and an electric motor vehicle and is used to minimize the damage of an occupant in the event of an accident. Airbag-related parts are being monopolized by a small number of foreign companies around the world. In this situation, it is necessary to develop and research the airbag-related part molding technology for expansion of the domestic airbag-related market and corporate export. As a part of this research, we have developed a mold for airbag inflator cap. The development consists of three steps which are the design of components, analysis of the design and verification of it. In the case of the design, the transfer type mold was designed for the multi-cylindrical shaped feature. Analysis was then conducted on the design. By examining the results of analysis, changing features and numbers of punches and dies were added in the analysis and repeatedly analyzed. After the addition, proper dimensions from the analysis were achieved, and prototypes were practically produced and verified. In the case of prototype verification, Pressurizing Burst Test was conducted on the existing products and the prototype. By comparing the results of the test, the possibility of replacing the existing product of the airbag inflator cap is presented in this paper.