• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.191-194
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• 2009

Very big springback in advanced high strength steel(AHSS) sheets invokes undesired shape defects, which can be eliminated by the tool surface correction method or the forming process control method. Since the springback reduction by controlling the forming process is limited, in this study, the die correction method which finds die correction from the relationship between die design variable and springback is introduced to achieve springback reduction and is applied to the automotive side rail to reduce the springback of 75.8% within the assembly limit of 1 mm.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.397-400
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• 2009

When the metal sheet is subjected to the housing surface for fitting and insulating from harsh surroundings like fluid ingression or hot steam, both strength and formability have to be equally considered. In this regard, the main aim of this study is to design an apparatus of cost-effectively producing flexible fluted band with increasing the formability of embossed stainless steel sheet, which is utilized as a thermal insulation metal for housing ship engine exhauster. Designed to fabricate a maximum sheet width of 700 mm, this new apparatus consists of upper roll made of hard urethane and the female-etched lower roll made of SKD11, have a producing capacity up to 1-meter homogeneously embossed sheet for just 60 seconds. This machine is devised for the maximum operating efficiency from original sheet handling to machine setting. The embossing properties are characterized by 3-D profiling. After embossing plain metal sheet, both yield strength and elongation properties are improved simultaneously, indicating the effectiveness of the newly designed apparatus.

• Transactions of Materials Processing
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• v.23 no.7
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• pp.446-452
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• 2014

In the current study finite element forming analysis is performed to understand the final geometric accuracy limitations for the stamping of an automotive S-rail from four different steel sheets having tensile strengths of 340MPa, 440MPa, 590MPa and 780MPa. Comparisons between the analysis and the experiments for both springback and formability as measured by the amount of edge draw-in and the thickness distribution were conducted. The springback modes were classified according to a scheme proposed in the current investigation and the error was calculated using the normalized root mean square error method. While the analysis results show fairly good agreement with the experimental data for deformation and formability, the simulation accuracy is lower for predicting wall curl, camber and section twist as the UTS of steel sheet increases.

• Transactions of Materials Processing
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• v.9 no.2
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• pp.140-151
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• 2000

The finite element mesh approach for tool surface description is applied effectively to analyze sheet metal stamping processes. To improve the mesh quality and the stability of the mesh generation process, a gybrid method based on the grid approach and the Delaunay triangulation is proposed in the present work. In the present study, a general method for the mathematical description of arbitrarily shaped tool surface is proposed by introducing the parametric surface approach. A polynomial function employed to describe the base parametric surface and the boundary curves are defined to describe arbitrary three-dimensional trimmed surfaces. To verify the validity of the proposed method, automatic mesh generation is carried out for some shosen complicated parts including actual automotive panel.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1996.03a
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• pp.159-164
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• 1996

For the purpose of establishing laser welding condition(laser power, welding speed and beam focus) and of evaluating tailor welded blank for three kinds of thin steel sheets of SPCC, SK5M and SUS304 using in the thin plate structure such as automobile, train and so on. Their $CO_2$ laser weldability were primarily tested under various welding condition. SPCC and SUS304 thin sheets showed good weldability under some welding condition. But, high carbon steel sheet SK5M needs heat treatment after welding to obtain higher tensile strength and ductility of the welded joint. And next, laser welding condition. Butt-welded specimens were not nearly broken at weld bead. However, base material were ruptured in the direction of circumference. The forming depths by tailor weld bead. However, base material were ruptured in the direction of circumference. The forming depths by tailor welded blank were SPCC+SPCC=22~25mm, SUS304+SUS304=25~43mm and SK5M+SK5M=13~17mm.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.1-8
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• 1998

The explicit and implicit time integration methods are applied effectively to analyze sheet metal stamping processes, which include the forming stage and the springback stage consecutively. The explicit time integration method has better merits in the forming stage including highly complicated three-dimensional contact conditions. By contrary, the implicit time integration method is better for analyzing springback since the complicated contact conditions are removd and the computing time to get the final static state is short. In this work, brief descriptions of the formulation and the factor study for springback simulations are presented. Further, the simulated results for the S-rail and the roof pannel stamping processes are shown and discussed.

• Transactions of Materials Processing
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• v.13 no.6 s.70
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• pp.528-534
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• 2004

In order to find the effect of lubricant viscosity, tool geometry, forming speed, and sheet material properties on the friction in the sheet metal forming, friction tests were performed. Friction test results show that as the lubricant viscosity becomes lower, the friction coefficient is higher. When surface roughness is extremely low or high, the friction coefficient is high. The bigger die corner radii and punch speed are, the smaller is the friction coefficient. From the experimental observation, the friction model which is the mathematical expression of friction coefficient in terms of lubricant viscosity, roughness and hardness of sheet surface, punch corner radius, and punch speed is constructed. By comparing the punch load found by FEM using the proposed friction model with that obtained from the experiment in 2-D stretch forming, the validity and accuracy of the friction model are demonstrated.

• Transactions of Materials Processing
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• v.14 no.6 s.78
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• pp.509-513
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• 2005

This paper is concerned with manufacturing technology of thin foil tensile specimen using CIP(Cold Isostatic Press) and measurement of precision mechanical properties using micro tensile testing. We can get a burr free micro metallic thin foil specimen using this technology. For testing mechanical property of this micro thin foil, we use a nano scale material testing machine that was developed by KITECH. In this paper, micro tensile specimens of nickel and copper thin foil are fabricated with CIP and precision mechanical properties of these materials could be measured. We will expect precision mechanical property of micro/nano material and component.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.134-137
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• 2005

In this paper, a continuous contact treatment has been considered during FE-analysis of the sheet metal forming processes. Because the simulation is usually performed stepwise, the status of contact can change suddenly. In case of implicit scheme, the increment of punch stroke can be chosen as large value. For exact assessment of contact force and friction force between die and sheet, the continuous contact treatment is proposed. The virtual surface of sheet metal is modeled by NURBS curves or surfaces in order to calculate exact contact area and penetration depth. From the geometrical evaluation of contact behavior, additional contact pressure is imposed to the element. The deformation of bending process and hydroforming process are analyzed based on this scheme.

• Transactions of Materials Processing
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• v.10 no.1
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• pp.59-66
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• 2001

Recently, the technology of incremental forming for sheet metal components has drawn attention for small-batch productions. In the present investigation, a forming tool containing a freely-rotating ball was developed and applied to forming of various shapes with full annealed Al 1050 sheet. Deformation characteristics occurring during forming with this tool was examined through FEM analysis and grid measurement. It was found that deformation modes developed along a straight path and around a corner are close to those of plane-strain and equi-biaxial stretching, respectively, and that cracks occur mostly at corners for the same depth of tool. FEM analysis was successfully applied to this special type of forming process and provided comparable results to the measurements from experiment.