• Journal of the Korean Society for Precision Engineering
• /
• v.15 no.4
• /
• pp.58-67
• /
• 1998

A sectional analysis of sheet metal forming process with an arbitrary tool shape is proposed in the present work. To improve the numerical convergence in the conventional membrane sectional analysis, the Bending Energy Augmented Membrane (BEAM) elements had been developed. The BEAM elements particularly improve the stability and convergence of the finite element method for the case of deep drawing. In this work, the FERGUBON spline (C$^2$-continuous) was used to fit the deformed mesh to smooth the given curves and calculate the local curvature of the deformed sheet. The fittings of the deformed sheet and tool surface profile ensure the stability and the convergence of the finite element analysis of highly nonlinear stamping processes. A center floor section and front fender section are analyzed to show the accuracy and robustness of the approach. The results obtained by the proposed approach are compared with the available experimental data.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.11a
• /
• pp.559-562
• /
• 2000

Bending is one of the most common cold-stamping operations, recently it is many used to produce structural frame. Depending on the shape and dimensions of complex structural frame, a successive bending operation with simple dies may be economic. But, in this paper, it has been focused to reduce the bending operations by a successive-action compound die. Designed compound-die consists of blank-holder, cam, wedge and etc. In the result, this compound-die for structural frame enabled that it makes seven bending processes into one process, and improved productivity.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1997.04a
• /
• pp.957-961
• /
• 1997

In this paper, an assessment has been proceeded about component technology that stamping car panel can be designed and manufactured efficiently. Also this study investigated srandard model of CAD/CAM system in production process of automobile dies. Recently, motor companies are doing their best to increase productivity and to reduce production time. So to develop user-friendly and effective standard model of CAD/CAM system is very important. The obtained results will lead to the reductions in lead time and man-hour required for the design and manufacture of the automobile dies.

• Transactions of Materials Processing
• /
• v.27 no.3
• /
• pp.171-176
• /
• 2018

In this study, the cooling characteristics of dies were investigated in the hot stamping process of front pillars for automobile. Two identical dies were manufactured out of tool steels with different thermal conductivities. The dies were designed with curved channels for uniform cooling of the blank. Computational fluid dynamics (CFD) simulations were also carried out, which can consider the heat transfer among the coolant, die, and blank. Measured and simulated thermal histories of dies were compared, and it was shown that high conductivity tool steel has an excellent cooling capacity compared to conventional tool steel.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1996.10a
• /
• pp.38-47
• /
• 1996

Sectional analysis program for plane strain or axisymmetric geometry of aluminum alloy sheet metals was developed. For modeling the anomalous behavior of aluminum alloy, Barlat's strain rate potential and Hill's 1990 non-quadratic yield theory arranged under the plane stress assumption were employed. 2-D rigid-viscoplastic FEM formulation based on the bending-augmented membrane theory was derived, solving simultaneously force equilibrium as well as non-penetration condition. Isotropic hardening law was also assumed for yielding behavior. To verify the validity and availability of the developed program, 2-D stretch/draw forming process for plane strain geometry and cylindrical cup deep drawing process for axisymmetric geometry were simulated.

• Transactions of Materials Processing
• /
• v.21 no.8
• /
• pp.485-492
• /
• 2012

As the shape of stamped part is complicated and as the trend toward light weight continues, the higher level of difficulty is required in making stamping die because of inevitably poor formability. The poor formability can be improved if the material flow during the stamping is carefully controlled. Application of drawbead became commonsense used to retard metal flow of blank into the die cavity at the region where wrinkle is expected. In the study, the concept of beadless stamping process is proposed and the method how to realize the beadless stamping process is presented. The validity of the proposed method is confirmed by the application of the real auto part.

• Transactions of Materials Processing
• /
• v.6 no.4
• /
• pp.279-290
• /
• 1997

The sectional forming analysis of stamping pocesses for aluminum alloy sheet metals was investigated. For the modeling of the anomalous behavior of aluminum alloy sheet. the Barlat's strain rate potential and Hill's 1990 non-quadratic yield theory with an isotropic hardening rule were employed. The rigid-viscoplastic FEM formulation which solves equilibrium equation for plane-strain stage with mesh-normal geometric constraints was derived. A new method to determine the Barlat's anisotropic coefficients was also suggested. To verify the validity of the formulation, the stretch and draw forming processes of a square cup were simulated.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.10 no.6
• /
• pp.1164-1169
• /
• 2009

In this study, the bracket for car was designed in 3D using Cimatron Die Design, one of the automatic modules. To facilitate the stamping of the product, the layout of the strip was adjusted slightly. The blank layout of the double-width, 2-line, 2-pull out inner carrier was then optimized as a single arrangement. 3D design was completed in 11 processes.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.9 no.3
• /
• pp.131-142
• /
• 2001

A wrinkling is the instability phenomenon influenced by material properties, shape geometry, forming conditions, stress state, etc. The wrinkling is considered as a critical defect in appearance of product. Many wrinkling prediction methods using thickness strain distribution and farming analysis have been proposed. The wrinkling, however, is not easily predicted precisely by these methods. In this study, the region in the biaxial plane stress state is modeled with a rectangular plate introducing the effective dimension, and critical stress values for the wrinkling are calculated. Prediction index for the wrinkling is then evaluated by normalizing the actual stress with respect to the critical stress. In order to show the validity and efficiency of the method proposed, the wrinkling prediction for a squared sheet in the uniaxial tensile stress and auto-body front finder panel is performed.

• Transactions of Materials Processing
• /
• v.25 no.6
• /
• pp.396-401
• /
• 2016

Recently, Multi-strength hot stamping process has been widely used to achieve lightweight and crashworthiness in automotive industry. In concept of multi-strength hot stamping process, process design of tailor rolled blank(TRB) in partial heating is difficult because of thickness and temperature variation of blank. In this study, springback prediction of TRB in partial heating process was performed considering its thickness and temperature variation. In partial heating process, TRB was heated up to $900^{\circ}C$ for thicker side and below $Ac_3$ transformation temperature for thinner side, respectively. Johnson-Mehl-Avrami-Kolmogorov(JMAK) equation was applied to calculate austenite fraction according to heating temperature. Calculated austenite fraction was applied to FE-simulation for the prediction of springback. Experiment for partial heating process of TRB was also performed to verify prediction accuracy of FE-simulation coupled with JMAK equation.