• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.121-124
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• 2003

A new form-joining process with the aid of an adhesive is proposed in which an epoxy adhesive is applied to a sheet metal pair, and before it cures the pair is clinched to cause the geometric constraint in the form of a protrusion. In order to reduce the forming load and the height of protrusions, a new die and punch set with a very small clearance was devised to reduce the depth of drawing and the forming load. Taguchi method was employed to find the optimal values of design parameters. To implement each case of the orthogonal array, the finite element method was used. The experiments showed that on the tensile-shear test, the bonding strength of the new form-joining process with an epoxy adhesive is approximately the same as that of the resistance spot welding; and in comparison with the other two form-joining processes with an epoxy adhesive, the height of protrusions was reduced by more than 65 percent and the forming load by 50 percent.

• Transactions of Materials Processing
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• v.19 no.1
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• pp.38-43
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• 2010

Electromagnetic forming (EMF) method is one of high-velocity forming processes, which uses electromagnetic Lorentz force. Advantages of this forming technique are summarized as improvement of formability, reduction in wrinkling, non-contact forming and applications of various forming process. In this study, the EMF apparatus is developed. It is designed to be stored in 10 capacitors connected in parallel, each with a capacitance of $50{\mu}F$ and maximum working voltage of 5kV. The system has capacitance of $500{\mu}F$ and maximum stored energy of 6.25kJ. And EMF experiments are carried out to verify the feasibility of the EMF apparatus, which has enough forming force from the results of EMF experiment. In addition, peak current carrying a forming coil is predicted from theoretical background, and verified the predicted value compared with experimental value using the current measurement equipment. Consequently, EMF apparatus developed in this study can be applied to various EMF researches for commercialization.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1992.03a
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• pp.201-212
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• 1992

The plane strain analysis for simulating the stretch/draw forming operation of arbitrarily-shaped tool profiles and arbitrarily draw-in conditions is introduced. An implicit, incremental, updated Lagrangian formulation is employed, introducing a rigid-viscoplastic constitutive equation. Contact and friction are considered through the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshe without depending on the explicit spatial derivatives of tool surfaces. The FEM formulation is tested in the sections automotive inner panel and two-side draw-in. Not only the excellent agreement between measured and computed strains in the stretched section is obtained, but also the numerical stability of current formulation is verified in the two-side draw-in section.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.439-442
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• 2003

This study presents a new computational model to analyze the grain deformation in a polycrystalline aggregate in a discrete manner and based directly in the underlying physical micro-mechanisms. As a result, specific characteristics have to be considered for the numerical analysis. The grains and grain boundary elements are introduced to model individual grains and grain boundary facets, respectively, to consider the size effects in the micro forming. The constitutive description of the grain elements accounts for the rigid-plastic and the grain boundary elements for elastic relationships. The capability of the proposed approach is demonstrated through application of grain element and grain boundary element in the micro forming.

• Transactions of Materials Processing
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• v.14 no.8 s.80
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• pp.668-674
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• 2005

In sheet metal forming, drawbeads are often used to control uneven material flow which may cause deffets such as wrinkles, fractures, surface distortion and springback. Appropriate setting and adjusting of the drawbead force is one of the most important parameters in sheet forming process control. Therefore in this study, drawbead friction test with circular shape bead was performed at various sheets, lubricants(dry, three kinds of lubricants having different viscosities), bead materials and surface treatments of bead surface. The results obtained by drawbead friction test show that the friction and drawing characteristics of deforming panels were mainly influenced by strength of sheet, viscosity of lubricant and hardness of bead surface.

• Transactions of Materials Processing
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• v.9 no.3
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• pp.293-303
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• 2000

Recent developments of Fe technology make it possible to apply CAD/CAE/CAM techniques successfully to the stamping die design among the automotive parts industries. Those successful applications are greatly attributable to the development of commercial S/W. Up to now most commercial S/W for the analysis of sheet metal forming is based on the dynamic explicit algorithm. The main characteristics of dynamic explicit algorithm is that there is no convergence problem if the time increment is taken less than the stability limit. The stability of the analysis is guaranteed in the commercial code, since the adequate time increment is computed from the so called "Courant Condition". However excess computing time is often pointed out in the dynamic explicit analysis according to the characteristics of process parameters taken. In the study, various parameters that may affect the stability and the method how to improve computational efficiency of analysis have been investigated.estigated.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.349-354
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• 2002

In order to find the effect of lubricant viscosity, sheet surface roughness, tool geometry, and forming speed on the frictional characteristics in sheet metal forming, a sheet metal friction tester was designed and manufactured and friction test of various sheet were performed. Friction test results showed that as the lubricant viscosity becomes lower, the friction coefficient is higher. When surface roughness is extremely low or high, the friction coefficient is relatively high. The result also show that as the punch radius and punch speed becomes bigger, the friction coefficient is smaller. Using experimental results, the mathematical expression between friction coefficient and lubricant viscosity, surface roughness, punch comer radius, or punch speed is also described.

• Transactions of Materials Processing
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• v.9 no.3
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• pp.274-283
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• 2000

A dynamic explicit finite element code for simulating sheet forming processes has been developed. The code utilizes the discrete Kirchhoff shell element and contact force is treated by a conventional penalty method. In order to reduce the computational cost, a new and robust contact searching algorithm has been developed and implemented into the code. In the method, a hierarchical structure of tool segments is built for each tool at the initial stage of the analysis. hierarchical structure is built in a way to divide a box to 8 sub-boxes, 2 in each direction, until the lowest level of the hierarchical structure contains exactly one segment of the tool or empty. Then at each time step, contact is checked from the box to sub-boxes hierarchically for each node. Comparisons of computational results of various examples with the existing ones show the validity of the method.

• Transactions of Materials Processing
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• v.12 no.1
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• pp.49-59
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• 2003

To reduce the cost of finite element analyses for sheet forming, a 3D hybrid membrane/shell method has been developed to study the springback of anisotropic sheet metals. In the hybrid method, the bending strains and stresses were analytically calculated as post-processing, using incremental shapes of the sheet obtained previously from the membrane finite element analysis. To calculate springback, a shell finite element model was used to unload the final shape of the sheet obtained from the membrane code and the stresses and strains that were calculated analytically. For verification, the hybrid method was applied to predict the springback of a 2036-T4 aluminum square blank formed into a cylindrical cup. The springback predictions obtained with the hybrid method was in good agreement with results obtained using a full shell model to simulate both loading and unloading and the experimentally measured data. The CPU time saving with the hybrid method, over the full shell model, was 75% for the punch stretching problem.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.339-342
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• 2003

This paper newly proposes a mesh regularization method for the enhancement of the efficiency in sheet metal forming analysis. The regularization method searches for distorted elements with appropriate searching criteria and constructs patches including the elements to be modified. Each patch is then extended to a three-dimensional surface in order to obtain the information of the continuous coordinates. In constructing the surface enclosing each patch, NURBS(Non-Uniform Rational B-Spline) surface is employed to describe a three-dimensional free surface. On the basis of the constructed surface, each node is properly arranged to form unit elements as close as to a square. The analysis results with the proposed method are compared to the results from the direct forming analysis without mesh regularization in order to confirm the validity of the method.