• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.50-55
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• 2008

CNC wire bending machines are used in industries to make a type variety of wire products such as long links. The machines have a long arm device to rotate in order to remove forming errors by flexibility of wire. Generally, the machines which constructed servo motors in the arm have the rotating range of the arm under 360 degree because the servo motors connect with fixed control devices on frame by many cables. The rotating angle under 360 degree limits working speed and forming geometry. Therefore this study developed a gear train to drive a parts in arm and to be independent on arm rotation movement. The developed gear train can transfer four movements to four components in arm and is consists parallel of four pairs of satellite gear trains. This study constructed the CNC wire bending machine with the developed gear train and verified that the gear train could drive internal components independently on arm rotation.

• Journal of Powder Materials
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• v.4 no.4
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• pp.258-267
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• 1997

The powder forging process is an attractive manufacturing route for bevel gears. It offers beneficial material utilization and the minimization of finishing operations over that of conventional hot forging. The paper describes the process conditions for the powder forging of bevel gear, for example, powder alloy design, preform design, deformation of sintered preform, forging processes. The characteristics of prototype gear are investigated with microstructure, the density distribution, surface roughness of tooth, bending strength test of tooth, etc. The results of the bending strength test may prove the mechanical properties of powder forged gear.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.336-339
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• 2007

In order to investigate the cause of fluting in tangential bending of low carbon steel sheet, an analytic analysis, an experiment and a series of finite element analysis for bending process were done. The fluting in bended sheet was due to the yield point elongation of material. Due to the yield point elongation, unstable plastic hinge was occurred in course of bending of elastic perfectly plastic sheet. According to the analysis and computational results, lower yield point elongation than 5% was required to prevent fluting in $0.5{\sim}0.6t$ sheet in $15{\sim}20mm$ radius bending.

• Journal of the Korea Institute of Military Science and Technology
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• v.3 no.1
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• pp.176-182
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• 2000

$360^{\circ}$ bending of Ti-6Al-4V large-diameter seamless tube(62.37 mm $OD {\times} 4.40mm$ wall thickness) has been achieved at room temperature without heating. The bending process comprised two steps : the first step is $360^{\circ}$ bending by an uniquely designed rotary bender allowing spring back, which is subsequently eliminated by the second or finishing step which comprised repeated bending processes by powered three roll bender, In odor to prevent collapse of tube during bending, Cerro $Tru^{TM}$(Trade name of a non-ferrous low melting point alloy)has been employed as a filler metal. The resultant ovality(out of roundness) obtained was 1.28%, as compared with 6~8% without applying Cerro $Tru^{TM}$.

• Transactions of Materials Processing
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• v.10 no.2
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• pp.91-100
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• 2001

A sectional FEA program is developed lot analyzing forming processes of sandwich sheets, which are intensively used recently as a lightweight material of an automobile body. The aluminum sandwich sheet consists of two aluminum skins and a polyprophylen core in between. The aluminum sandwich sheet is dominantly effected by the bending effects in small radius of curvature, so that an appropriate description of bending effects is required to analyze the forming processes. For the evaluation of bending effects, the bending equivalent forces are calculated from the bending moment computed using the curvature of the tool and are added to the membrane stretch forces. To verify the validity of the developed program the sectional FEA results in stretch/draw forming Processes of a square cup and draw forming Processes of an outer hood panel were compared with the measurements.

• Transactions of Materials Processing
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• v.13 no.5
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• pp.409-414
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• 2004

TRIP steel has got attention in automobile industry because of its high strength and high formability. However, the information on deformation behavior of TRIP steel, including bending and springback, is not enough until now. In this research, the V-die bending experiment and analysis have been done to obtain the information of springback of TRIP steel. And a new numerical method, where elastic modulus is varied with the change of the strain, was suggested. Tensile test for TRIP steel was done to get tensile properties as well as strain dependency of elastic modulus of the material. Strain-dependency of elastic modulus was used the numerical analysis of V-die bending and unbending process to predict springback amount. The results were compared with experiment, showing reasonable agreement. Through the analysis of V-die bending as well as draw bending of TRIP steel, the proposed scheme with variable elastic modulus was proven to well predict the deformation behavior of TRIP steel during bending and springback.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.2
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• pp.71-77
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• 2009

In the automotive industry, aluminum is widely used to reduce the vehicle weight. Aluminum curved extruded components are used for the design of frame parts. This study investigates the curvature extrusion process to produce the aluminum curved suspension arm. In the curvature extrusion process, the bending process is simultaneously carried out with the extrusion process. Firstly, porthole extrusion was investigated by using FE analysis to produce aluminum suspension arm. And then the bending process condition was determined to produce the final suspension arm with the required curvature. In this research, the guide roll movement causes the bending of extruded product. The moving distance and velocity of guide roll were controlled to meet the required curvature of suspension arm. Finally, the curved suspension arm was manufactured by the curvature extrusion experiment under the proposed curvature extrusion condition.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.5
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• pp.502-507
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• 2009

Curvature extrusion process has several advantages in comparison to the conventional extrusion and bending process. In the curvature extrusion, the extruded part is directly bent during extrusion. Therefore, it does not need additional bending process after extrusion. In the curvature extrusion process, it is possible to produce curved extruded products that have a constant or various curvatures. It is essential that we predict the curvatures of the extruded product to meet the required curvatures. This paper proposed a theoretical model that can predict the curvature of extruded product produced by the curvature extrusion process. Using the proposed model the movement of guide tool that causes the bending of extruded product was controlled to produce the required curved automotive Al bumper back beam. The effectiveness of the proposed prediction model and the movement of guide tool were verified by the FE analysis and curved extrusion experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.293-296
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• 2009

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal front side member manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle. And also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.307-310
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• 2009

Nowadays, the usage of high strength steel has been growing in automobile industry mainly as structural parts since for its lightweight and high strength properties the oil crisis happened. Owing to poor formability, complex-shaped high-strength steel components are invariably produced through hot press forming. The high-strength steel sheets are in so me instances used with an Al-Si-coating with a view to prevent scaling of components during hot press forming. How ever, friction and fracture characteristics of Al-Si-coated high-strength steel during hot press forming process have not yet been investigated. In this paper, the formed parts which were formed in hot bending process were investigated by using EDS. SEM and nano indenter in order to analysis the coating layer behavior.