• 한국정밀공학회지
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• 제16권11호
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• pp.122-132
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• 1999

This study describes a dynamic model of the hydroforming process which is used for precision forming of sheet metals. To help the controller design for the control of the forming pressure needed for this process as well as to investigate the effect of system parameters on the dynamic behavior, dynamic modeling is performed with emphasis on hydraulic servo system which actuates the forming machine. Since the model contains several unknown parameters, these were estimated via a least square parameter identification method. Based upon the identified model, a series of simulations were performed for various operating conditions. The results were compared with those of the experiments to verify the validity of the proposed model. The comparison study shows that the proposed dynamic model can describe dynamic behavior of the forming pressure of the hydroforming process to desirable accuracy.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1989년도 한국자동제어학술회의논문집; Seoul, Korea; 27-28 Oct. 1989
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• pp.302-307
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• 1989

A pressure tracking control of hydroforming process is considered in this paper. To account for nonlinearities and uncertainties of the process, an iterative learning control scheme is proposed using Cerebellar Model Arithmatic Computer (CMAC). The experimental result shows that the proposed learning control is superior to any fixed gain controller in the sense that it enables the system to do the same work more effectively as the number of operation increases.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1987년도 한국자동제어학술회의논문집; 한국과학기술대학, 충남; 16-17 Oct. 1987
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• pp.317-323
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• 1987

A pressure tracking control of hydroforming processes, which is used in the precision forming of. sheet metals, is considered in this paper. The hydroforming of sheet metal is performed between the high-pressure chamber controlled by pressure control valve and the punch moving with constant speed. Since the pressure in the forming chamber is a critical factor to the quality of the product severely. It is important to control the pressure to follow a prescribed pressure trajectory, depending upon the material volume and shape of the parts to be formed. Taking into consideration of the volume chamge of forming chamber during the process and the nonlinearity of the electro-magnetic relief valve, a mathematical formulation of the model describing the dynamic characteristics of this model obtained. Based upon this model a PID controller is designed for the pressure tracking.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2003년도 추계학술대회
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• pp.1810-1815
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• 2003

Tube hydroforming provides a number of advantages over conventional stamping process, including fewer secondary operation, weight reduction, assembly simplification, adaptability to forming of complex structural components and improved structural strength and stiffness. In this study, the effect of the heat treatment on the hydro-formability has been investigated. By using the mild steel tube bulging test is performed at various heat treatment conditions to evaluate the hydro-formability.

• 소성∙가공
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• 제9권1호
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• pp.35-42
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• 2000

In this paper, we developed the hydroforming simulator which can apply an axial compressive force and high internal pressure to bulge a tube. Experimental dtudies have been performed to investigate the effect of each parameters such as internal pressure and axial compression stroke required for the forming of circular components. Under the improper forming conditions there were two forming failures. One was the axial buckling due to excessive axial compressive load and the other was the circumferential necking fracture due to relatively high internal pressure. A safe forming zone without any failures exists between these two extreme zones. Also the condition of forming failure such as fracture is examined throughout the theoretical analysis. This paper covers a brief overview of the mechanism of hydroforming process as well as the design of die and tools.

• 한국정밀공학회지
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• 제17권4호
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• pp.22-28
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• 2000

By using the finite element method, the Oyane's ductile fracture integral I was calculated from the histories of stress and strain according to every element and then the forming limit of hydroforming process could be evaluated. The fracture initiation site and the forming limit for two typical hydroforming processes, tee extrusion and bumper rail under different forming conditions are predicted in this study. For tee extrusion hydroforming process, the pressure level has significant influence on the forming limit. When the expansion area is backed by a supporter and bulged, the process would be more stable and the possibility of bursting failure is reduced. For bumper rail, the ductile fracture integral i is not only affected by the process parameters, but also by the shape of preforming blank. Due to no axial feeding on the end side of the blank, the possibility of cracking in hydroforming of the bumper rail is influenced by the friction condition more strongly than that of the tee extrusion. All the simulation results show reasonable plastic deformation, and the applications of the method could be extended to a wide range of hydroforming processes.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.310-313
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• 2007

This paper covers finite element simulations to evaluate the bending limit of double pipe for tube-hydroforming. The tube-hydroforming process starts with a straight precut tube. The tube is often prebent in a rotary draw bending machine to fit the hydroforming tool. During the bending the tube undergoes significant deformation. So forming defects such as wrinkling, thinning and flattening are generated in the tube. Consequently we analyzed the effect of process parameters in rotary draw bending process and searched the optimized combination of process parameters to minimize the forming defects using orthogonal arrays. The characteristic to evaluate the effects of the process parameters is the bending angle which wrinkling is generated, we define the bending angle at that time as bending limit. Of many process parameters, the process parameters of the bending process such as gab between inner and outer tube, boosting force, dimensions of mandrel were analyzed. And we observed the deformation modes of bent double pipe at specific bending angle in each parameter combination.

• 제어로봇시스템학회논문지
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• 제6권3호
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• pp.329-337
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• 2000

This study describes a pressure tracking control of hydroforming process which is used for precision forming of sheet metals. The hydroforming operation is performed in the high-pressure chamber strictly controlled by pressure control valve and by the upward motion of a punch moving at a constant speed, The pressure tracking control is very difficult to design and often does not guarantee satisfactory performances be-cause of the punch motion and the nonlinearities and uncertainties of the hydraulic components. To account for these nonlinearities and uncertainties of the process and iterative learning controller is proposed using Cerebellar Model Arithmetic Computer (CMAC). The experimental results show that the proposed learning control is superior to any fixed gain controller in the sense that it enables the system to do the same work more effectively as the number of operation increases. In addition reardless of the uncertainties and nonlinearities of the form-ing process dynamics it can be effectively applied with little a priori knowledge abuot the process.

• 대한기계학회논문집A
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• 제34권7호
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• pp.905-910
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• 2010

일체형 배기다기관은 하이드로 포밍 대량 생산이 가능한 부품으로 국내, 국제적인 환경문제에 따른 배출 규제와 매우 밀접한 관계에 있기 때문에, 국내 완성차 업체에서 큰 관심을 가지고 있다. 일반적인 주조부품과 비교해서 관형 배기다기관은 용접공정 감소에 따른 단순화된 제작 공정 뿐만아니라, 엔진 시동시 가스 분해능이 우수한 특징을 가지고 있다. 본 연구는 부품, 공정, 금형 설계를 포함하는 배기다기관을 개발하는데 목적이 있다. 배기 시스템의 성능은 유동해석, 열전달, 열응력, 내구해석 시뮬레이션을 통해 평가하였다.

• 한국자동차공학회논문집
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• 제18권5호
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• pp.45-49
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• 2010

The automotive industry has shown a growing interest in tube hydroforming during the past years. The advantages of hydroforming (less thinning, a more efficient manufacturing process, etc.) can, for instance, be combined with the high strength of extra high strength steels, which are usually less formable, to produce structural automotive components which exhibit lower weight and improved service performance. Design and production of tubular components require knowledge about tube material and forming behavior during hydroforming and how the hydroforming operation itself should be controlled. These issues are studied analytically in the present paper. In this study, the whole process of rear sub-frame parts development by tube hydroforming using AA6061 material is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Engineering) to confirm hydroformability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape in automotive rear sub-frame by hydroforming process were carefully investigated. Overall possibility of hydroformable rear sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending and hydroforming. In addition, all the components of prototyping tool are designed and interference with press is examined from the point of geometry and thinning.