• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.1
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• pp.88-99
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• 1996

The explicit scheme for finite element analysis of sheet metal forming problems has been widely used for providing practical solutions since it improves the convergency problem, memory size and computational time especially for the case of complicated geometry and large element number. The explicit schemes in general use are based on the elastic-plastic modeling of material requiring large computataion time. In the present work, a basic formulation for rigid-plastic explicit finite element analysis of plain strain sheet metal forming problems has been proposed. The effect of some basic parameters involved in the dynamic analysis has been studied in detail. Thus, the effective ranges of parameters have been proposed for numerical simultion by the rigid-plastic explicit finite element method. A direct trial-and-error method is introduced to treat contact and friction. In computation, sheet material is assumed to possess normal anisotropy and rigid-plastic workhardening characteristics. In order to show the validity and effectiveness of the proposed explicit scheme, computations are carried out for cylindrical punch stretching and the computational results are compared with those by the implicit scheme as well as with a commercial code. The proposed rigid-plastic exlicit finite element method can be used as a robust and efficient computational method for analysis of sheet metal forming.

• Transactions of Materials Processing
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• v.13 no.2
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• pp.122-128
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• 2004

In order to make a doubly-curved sheet metal effectively, a sheet metal forming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation in thickness. The developed process is an unconstrained forming process with no holder. For this study, the experimental equipment is set up with the roll set which consists of two pairs of support rolls and one center roll. In the experiments using aluminum sheets, it is found that the curvature of the formed sheet metal is determined by controlling the distance between supporting rolls in pairs and the forming depth of the center roll and it also depends on the thickness of the sheet metal. In order to check the effect of process parameters on the generation of sheet metal curvatures in this process, the orthogonal array is adopted. From the experimental results, among the process parameters, the distance between supporting rolls in pairs along the direction of one principal radius of curvature as well as the forming depth and the thickness of the material is shown to influence the generation of curvature in the same direction significantly. That is, the other distance between supporting rolls in pairs which are not located in the same direction of one principal radius of curvature, does not have an significant effect on the generation of the curvature in that direction. It mainly affects the generation of curvature in its own direction with the forming depth and the thickness of the material.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.08a
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• pp.53-57
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• 2003

In order to make a doubly curved sheet metal effectively, a sheet metal farming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation to thickness. The developed process is an unconstrained forming process with no holder. For this study, the experimental equipment is set up with the roll set which consists of two pairs of support rolls and one center roll. In the experiments using aluminum sheets, it is found that the curvature of the formed sheet metal is determined by controlling the distance between supporting rolls in pairs and the forming depth of the center roll and it also depends on the thickness of the sheet metal. In order to check the effect of process parameters on the generation of sheet metal curvatures in this process, the orthogonal array is adopted. From the experimental results, among the process parameters, the distance between supporting rolls in pairs along the same direction of one principle radius of curvature as well as the forming depth and the thickness of the material is shown to influence the generation of curvature in the same direction significantly. That is, the other distance between supporting rolls in pairs which are not located in the same direction of one principle radius of curvature, does not have an significant effect on the generation of the curvature in that direction. It just affects the generation of curvature in its own direction mainly with the forming depth and the thickness of the material.

• Journal of Welding and Joining
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• v.28 no.4
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• pp.73-80
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• 2010

In this work, the effect of welding variables on weldability of gas tungsten arc(GTA) welding was investigated with experimental analysis for a commercial pure(CP) titanium (Grade.1). The GTA welding tests on sheet samples with 0.5mm in thick were carried out at different process variables such as arc length, welding speed and electrode shape. In order to search an optimum arc length with full penetration, bead- on-plate welding before butt-welding were performed with different arc length conditions. From the bead- on-plate welding results, the optimum condition considering arc stability and electrode loss was obtained in the arc length of 0.8mm. Butt-welding tests based on the arc length of 0.8mm were carried out to achieve the optimum conditions of welding speed and electrode shape. Optimum conditions of welding speed and electrode shape were suggested as 10 mm/s and truncated electrode shape, respectively. It was successfully validated by the microstructural observation, tensile tests, micro-hardness tests and formability tests.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.2
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• pp.349-355
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• 2017

Bending work using press dies involves bending a flat blank to a desired angle. The bending produces a flange (the bent part) and a web (the unbent part). The bending line will have a bending angle, and there is an inner and outer bending radius. The minimum inner radius size is determined by the material used. When the inner radius size is too small, there will be excess metal welding, which will cause a crack in the outer radius part. The outer bending radius size cannot be controlled by a bending punch and die block. Types of bending include V-bending, U-bending, O-bending, edge bending, twist bending, and crimping. Z-bending involves two bending lines, which are set on the upper side and under surface of the blank, respectively, and upward or downward bending is used. Z-bending is also called crank bending. Z-bending using this type of die structure will produce a standard inner bending radius. The standard size is the minimum bending radius that represents the angle radius of the bending punch. In industry, there is a need for a sharp edge shape with a very small size (R=0.2mm), but that is not possible when using bending punch and die block. The purpose of this research is to meet the need by development.

• Journal of Korean Society of Steel Construction
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• v.18 no.5
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• pp.543-551
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• 2006

Cold-formed steel studs that are being used as load-bearing members of wall panels for steel houses have a problem with their insulation due to the heat bridging of their web. Some additional thermal insulating materials should be used. To solve this problem, the new-concept hybrid stud, which consists of a galvanized steel sheet (t = 1.0 m - 12.0 m) and a GFRP panel (t = 4.0-6.0 mm), has recently been developed. An investigation on the structural behavior and the strength capacity of this new hybrid stud has been conducted so that it can be used in load-bearing wall panels of residential buildings. This paper describes the axial compression-torsion test results of the hybrid studs under both axial compression and torsion using ATTM. The main factors of the test were the stud length, the magnitude of the initial compressive force, and the loading method of the monotonic or cyclic loading. The torsion was applied increasingly while the initial compression was kept constant to the failure of the hybrid section. The advanced analysis results obtained form the finite element procedure that considered the material properties of the high-strength galvanized steel and the GFRP were compared with the test results for verification.