• Transactions of Materials Processing
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• v.7 no.3
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• pp.225-232
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• 1998

This article is aimed primarily at establishing a process planning method for complex circular shells. For the deep drawing of complex shaped shell, the optimum process design is required to reduce the trial cost improve the quality, increase the productivity and shorten the delivery. The present approach which is related to the optimum process planning is based on the empirical knowledge through trial and error in the industrial field. In order to check the validity and the effectiveness of proposed work a sample process design has been applied to the multi-stepped deep drawing of com-plex shell considering the process variables such as drawing rate radius and blank development. In particular the difference between the limiting drawing rate and to optimum drawing rate has been discussed and the usefulness of present suggestion has been shown.

• Transactions of Materials Processing
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• v.16 no.5 s.95
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• pp.401-405
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• 2007

Due to the low densities and high specific strength and stiffness, magnesium alloy sheets are very attractive lightweight materials for automotive and electrical products. However, the magnesium alloy sheets should be usually formed at elevated temperature because of their poor formability at room temperature. For the use of the magnesium alloy sheets for an industrial, their mechanical properties at elevated temperature and appropriate forming process conditions have to be developed. In this study, non-isothermal simulation of a square cup drawing of magnesium alloy sheets have been conducted to evaluate a proper forming process conditions such as the tool temperature, the tool shoulder radius, friction between the blank and the tools. According to this study, appropriate forming process conditions of square cup drawing at elevated temperature from magnesium alloy sheets are suggested.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.03a
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• pp.118-128
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• 1994

The planar anisotropic FEM analysis for predicting the earing profiles and draw-in amounts in the deep-drawing processes is introduced. An implicit, incremental, updated Lagrangian formulation with a rigid-viscoplastic constitutive equation is employed. Contact and friction are considered through the mesh-based unit vectors and the normal contact pressure. the consistent full set of governing relations, comprising equilibrium and geometric constraint equations, is appropriately linearized. Barlat's strain-rate potential is employed, whose in-plane anisotropic properties are taken into account with anisotropic coefficients and potential parameter. The linear triangular membrane elements are used for depicting the formed sheet. with the numerical simulations of deep drawing processes of flat-top cylindrical cup for the 2090-T3 aluminum effects on the earing behavior are examined. Earing predictions made for the 2090-T3 aluminum alloy sheet show good agreement with experiments, although some discrepancies were observed in the directional trend of cup height and thickness strains.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.230-233
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• 2007

Due to their low density, high specific strength and electromagnetic interference shielding, magnesium alloy sheets are used increasingly more often in automotive, aerospace, and electronics industries. However, magnesium ally sheets should be usually formed at elevated temperature because of their poor formability at room temperature. For the use of magnesium alloy sheets for an industrial, their mechanical properties at elevated temperature and appropriate forming process conditions have to be developed. In this study, the warm deep drawing process of AZ31 sheets is studied numerically by non-isothermal simulation. The difference between the isothermal simulation results and the non-isothermal simulation results and the progress of warm forming are discussed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.7
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• pp.2246-2256
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• 1996

To investigate the effect of material and precess variables on stamping formability of sheet materials, simulations for the cup drawing and the Yoshida buckling test were carried out using ABAQUS, commercial nonlinear finite element analysis code. The various factor effects on stamping formability of sheet materials were analyzed by the designed process according to Taguch's orthogonal array experiment. Cup drawing simulation showed that local neckling was very sensitive to plastic anisotropy parameter of sheet material and friction coefficient between sheet and tool interface. Simulations for the Yoshida buckling test have clarified that buckling behaviour of sheet material was mostly susceptible to yield stress and sheet thickness mostly. However, plastic anisotropy parameter and strain hardening coefficient affect moderately buckling behaviour of steel sheets after the buckling initiation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.149-153
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• 2008

Since magnesium alloy sheets have been employed in industrial field which requires the light weight and thin engineering components, most of researches have been focused on the formability of magnesium ahoy sheet. In warm press forming of magnesium alloy sheet, it is important to control the sheet temperature by heating the sheet in closed die. When forming a commercial AZ31 magnesium alloy sheets which are 0.5mm and 1.0mm thick, respectively, time arriving at target temperature and temperature variation in magnesium alloy sheet have been investigated. Sheet metals were mostly formed in simple shapes such as circular or rectangular. Few studies about forming of complex shapes were reported. Thus, the formability of magnesium alloy sheet for complex shapes is investigated. The process variable for a double sink shape deep drawing with circular and rectangular shape was investigated by varying temperature, velocities, and clearances. Accordingly, temperature, velocities, and clearances suitable for forming were suggested through investigating the thickness variation of the product.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.586-593
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• 2008

In warm press forming of magnesium alloy sheet, it is important to control the sheet temperature by heating the sheet in closed die. When forming a commercial AZ31 magnesium alloy sheets which are 0.5mm and 1.0mm thick, respectively, time arriving at target temperature and temperature variation in magnesium alloy sheet have been investigated. The deep drawing process with rectangular shape alone at the first stage and with both circular and rectangular shapes at the second stage was employed. At the first stage, through deep drawing process with rectangular shape alone according to various forming temperature($150{\sim}350^{\circ}C$) and velocity($0.1{\sim}1.0mm/s$), optimum forming condition was obtained. At the second stage, deep drawing process with the circular and rectangular shapes were performed following deep drawn square cups with Limited Drawing Height(LDH) obtained at the first stage. Here, clearance which is defined a gap between the die and the punch including sheet was set to ratio of 20, 40 and 100% to thickness in sheet. Accordingly, temperature, velocities, and clearances suitable for forming were suggested through investigating the thickness variation of the product.

• Transactions of Materials Processing
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• v.24 no.1
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• pp.5-12
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• 2015

In the current study, fundamental deep drawing characteristics of Ti-6Al-4V alloy sheets were investigated to establish the effect of processing conditions on large size square deep drawn cups. To accomplish this study, FE-simulations (Abaqus) were performed to determine optimum blank size, friction coefficient, the gap between punch and die, etc. The simulated processing parameters were verified experimentally. Based on the FE-simulation results, deep drawing was performed with various blank holding loads and sample sizes. In order to improve the formability of Ti-6Al-4V sheet, various lubricant methods were evaluated. Tensile tests and thickness measurements were conducted on the formed sheets. Processing parameters including blank holding force, lubricants, and optimum blank size, were selected to achieve improved drawing quality. With the optimum processing condition, a $200mm{\times}200mm$ cup was deep drawn successfully.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.340-343
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• 2007

This paper introduces a new approach to consider the bending history in finite element inverse analysis of the cylindrical cup drawing. A modified membrane element is adopted to add the bending-unbending energy to the total plastic energy on the bending-unbending region predicted from the geometry of the final shape and tools. The algorithm suggested was applied to a cylindrical cup deep drawing process. The blank shape and the distribution of the thickness strain are compared with those obtained from incremental finite element analysis. The comparison demonstrates the algorithm proposed reduces the difference between the results from inverse analysis and those from incremental analysis when the bending history is considered.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.306-309
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• 2007

Recently, magnesium alloys have been widely used in automotive, aerospace and electronic industries with the advantages such as lightweightness, high specific strength and stiffness. However, magnesium alloy has quite low formability at room temperature due to its hexagonal close-packed crystal structure. Warm deep drawing is one of the forming technologies to improve the formability of magnesium alloy sheet and the lubrication condition is an important process parameter in that. In this study, the drawing tests of AZ31 alloy sheet at elevated temperature for various kinds of lubricant were carried out and the effects of lubrication conditions on drawbility were investigated.