• Transactions of Materials Processing
• /
• v.23 no.2
• /
• pp.103-109
• /
• 2014

Flexibly-reconfigurable roll forming (FRRF), which is a sheet forming process for multi-curved sheet metal, may solve both the economic and technical problems incurred in using a conventional die forming process. In the FRRF process, the multi-curved sheet metal is formed by different strain distributions on the sheet metal, and the reconfigurable rollers are used as tools during the forming. Therefore, a thorough investigation focused on the reconfigurable rollers is required for the realization of the FRRF process prior to the fabrication of FRRF machine. In the current study, a series of finite element simulations were conducted to study the load distributions experienced by the reconfigurable roller. In order to verify the shape design variables, the effect of the metal thickness on the curvatures of sheet is also presented.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2005.05a
• /
• pp.423-427
• /
• 2005

Sandwich structures, which are composed of a thick core between two thin faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Depending on the application of a particular sandwich structure, various types of cores can be used. The production of sandwich sheets by a rolling process, which is a more efficient and economical approach compared to other types of processes, has become an increasingly important subject of study. In this paper, we have studied the embossing structure of sheet type and developed embossing roll mold with $\Phi3$ pattern and roll forming system.

• International Journal of Automotive Technology
• /
• v.7 no.2
• /
• pp.209-216
• /
• 2006

A study has been conducted for an optimal processing and an apparatus for manufacturing a laser welded tube for one-body formed bumper beam. The tube dimensions used in calculation were the thickness of 1.4 mm, the diameter of 105.4 mm and the length of 2000 mm. The tube was formed of a cold rolled high strength steel plate(tensile strength of 600 MPa). The two-roll bending method was the optimal tube forming process in comparison with the UO-bending method, the bending method on the press brake, the multi-step continuous roll-forming method and the 3-roll bending method. Monitoring of the welding quality was conducted and the seam tracking along the butt-joint lengthwise to the tube axis was also examined. The longitudinal butt-joint was welded by using a $CO_2$ laser welding machine equipped with a seam tracker and a plasma sensor. The $CO_2$ laser tube welding machine could be used for precise seam tracking and real-time monitoring of the welding quality. As a result, the developed laser welded tube could be used for a one-body formed automobile bumper beam.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2002.10a
• /
• pp.53-57
• /
• 2002

Brake tube is considered one of the most important parts in automobile. The shape of brake tube-end has a great influence on the function of brake, and the quality and productivity of brake tube have relation to die design. The forming process of brake tube-end is peformed by hydraulic press forming machine. In this paper, the forming processes of tube-end for automobile is analyzed and designed to make the optimal form of brake tube-end. Also, finite element analysis has been carried out using DEFORM-3D$\^$TM/ to predict the optimal shape of brake tube-end and the results obtained showed the optimal length between punch and chuck is 1.0 ∼ 1.2mm. The shape of tube-end is in good agreement with the finite element simulations and the experimental results.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.16 no.10
• /
• pp.6977-6984
• /
• 2015

It is faced with the necessity of multi roll forming process of the ball slide rail which is made by adding the separate manufacturing processes, piercing, bending, trimming, to the roll forming process of a continuous plastic deformation, to improve the quality. However, the vibration and noise of the press machine in this process leads to the quality degradation of slide rail manufactured in this process. In this study, the roll was designed considering the optimal strain rates by the roll forming program with finite element method. And to estimate the static stability of the multi process the Von-Mises stress and deformation on the press was calculated with a structural analysis program. Also, to avoid driving systems in the resonance region their natural frequencies in the 1st and 2nd mode were calculated through the modal analysis. To verify its dynamic stability improvement the magnitudes of noise and vibration in the existing and studied system were compared using a microphone and accelerometers. And the widths and surface roughnesses of the rails which had been produced in the existing and studied process were measured. Therefore, it is known that multi roll forming process is stable in the analytical and experimental study.

• Journal of Power System Engineering
• /
• v.6 no.3
• /
• pp.31-35
• /
• 2002

Brake tube is considered one of the most important parts in automobile. The shape of brake tube end has a great influence on the function of brake, and the quality and productivity of brake tube have relation to die design. The forming process of brake tube end is performed by hydraulic press forming machine. In this paper, the forming processes of tube end for automobile is analyzed and designed to make the optimal form of brake tube end. Also, finite element analysis has been carried out using $DEFORM^{TM}% 3D to predict the optimal shape of brake tube end and the results obtained showed the optimal length between punch and chuck is $1.0{\sim}1.2mm$. The shape of tube end is in good agreement with the finite element simulations and the experimental results.

• Journal of the Society of Naval Architects of Korea
• /
• v.33 no.4
• /
• pp.142-149
• /
• 1996

Pyramid type three roll bending machines are widely used in roll-bending process to produce singly curved plate. In forming singly curved plate, controlling the vertical displacement of the center roller is most important to acquire the shape required and automation system of the process. In this paper roller bending process is modeled as an elastic-plastic phenomenon and analyzed using beam theory and finite element method. In finite element analysis the workpiece is modeled by using beam elements and plane strain elements respectively. Through the analyses vertical center roller displacement is obtained to get constant curvature distribution along arc length. The relationship between center roller displacement and curvature in steady state as well as residual stress and strain along plate thickness direction are calculated through finite element analysis.

• Journal of Power System Engineering
• /
• v.20 no.5
• /
• pp.5-13
• /
• 2016

This study is on wear damage of the material for a molding machine that be used at finally cutting of metal beam made in roll forming process of vehicle bump beam process line. SKD11 steel was used with the material for cutting mold jig. In the cutting mold jig, Ti diffusion heat treatment after vacuum heat treatment was carried out for upgrade of surface hardness and anti-wear. Also, the heat treatments by various methods were performed to compare the wear damage degree against above the existing heat treatment. Wear loss and friction coefficient were obtained from wear test. And, micro Vickers hardness values were compared with damaged parts or not of cutting mold jig. Micro Vickers hardness value appeared higher at the undamaged part by Ti diffusion heat treatment. The micro Vickers hardness well followed a two-parameter Weibull probability distribution.

• 제어로봇시스템학회:학술대회논문집
• /
• 1996.10b
• /
• pp.1476-1479
• /
• 1996

The ring rolling process is one of the best known ring production method. The present model based control system was designed for rings with rectangle cross-section yet. An Adaptive Fuzzy Control for Closed-Die Ring-Rolling was developed in order to enhance the flexibility of the radial-axial ring rolling machine and to produce the rings with highly complex cross-section profile, roller bearing rings. A fuzzy method was implemented because of its simple application and to utilize the known process knowledge. The quality of the control system was estimated by die filling grad, which is strong dependent on the rising time of the controller. The rolling process parameters were also varied to determine their influence on filling of the ring profile. Die filling met the requirement of the industry.