• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.9
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• pp.1-6
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• 2018

Hydro-forming technology has spread dramatically throughout automotive industry over the last 20 years. This technology has many advantages for automotive applications in terms of better structural integrity of the parts, lower cost from fewer parts, material savings, weight reduction, lower springback, improved strength, durability, and design flexibility. In this study, various simulation technologies were developed to investigate the formability of hydro-forming components. Through this technology, to establish the effective forming process for appropriate components design, the bending process, pre-forming process, die closing process, etc. were considered for good forming. This paper proposes the forming amount, section length (corresponding to the hydro-forming press capacity), and minimum curvature (curvature effect evaluation according to the hydro-forming pressure) among the considerations in the design of the hydro-forming part. In addition, a design method is proposed for hydro-forming molding by carrying out cross section analysis of a real sub-frame part for automobiles. The effects of pre-bending, axial feed, hydraulic pressure, press load, and friction among the hydro-forming process parameters were analyzed. Therefore, whether these processes are necessary factors for hydro-forming were examined.

• Korean Journal of Computational Design and Engineering
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• v.21 no.3
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• pp.234-241
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• 2016

Conventional bent plate used in mandibular reconstruction surgery needs safety verification since its mechanical properties are changed due to the plastic deformation during the bending process. In this study we investigate stability of the plastically deformed plate and the plate with the same shape without plastic deformation through the finite element analysis(FEA). First we simulate the process of plate bending to fit the defect in patient. Then, the other plate is modelled to represent a customized plate with the same shape of the plastically deformed one, but without any residual stresses from plastic deformation. After binding these plates to the mandible, we conduct the masticatory simulation. Finally, we compare the resulting Von Mises stress of the customized plate and of the bent plate. The bent plate shows much higher stress than the customized one due to the residual stresses form the bending process. The study shows that plastic deformation in the plate may decrease the safety of the reconstruction surgery.

• Journal of the Society of Naval Architects of Korea
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• v.45 no.4
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• pp.417-425
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• 2008

In the line heating process, only angular distortion whose direction is perpendicular to that of a heating path is expected. However, it is observed that a deformation is induced in the direction of the heating line. Because of this, during forming a saddle type plate we experience unfavorable deformations in the unintended direction. In this paper we discuss the unwanted distortion in the manufacturing process by analyzing intermediate plates of saddle type during fabrication. For this analysis we consider the longitudinal and transversal directions separately and use the bending strain for the analysis.

• Korean Journal of Metals and Materials
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• v.48 no.7
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• pp.683-689
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• 2010

In this study, FeAl based intermetallic matrix composites reinforced with in-situ synthesized TiC particles were fabricated by an in-situ liquid mixing process. The microstructures, mechanical properties and fracture behaviors of the in-situ liquid mixing processed composite were investigated and compared with the vacuum suction casting processed composite. The results showed that the in-situ formed TiC particles exhibited fine and uniform dispersion in the liquid mixing processed composite, while significant grain boundary clustering and coarsening of TiC particles were obtained by the vacuum suction process. It was also shown in both types of composites that the hardness and bending strength were increased with the increase of the TiC volume fractions. Through the study of fractography in the bending test, it was considered that the TiC particles prohibited brittle intergranular fracture of FeAl intermetallic matrix by crack deflections. Because of the uniformly distributed fine TiC particles, the bending strength of the liquid mixing processed composite was superior to that of the casting processed composite.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.82-87
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• 2012

The purpose of this study is to produce a side impact beam with high tensile steel using a roll forming process. The door side impact beam plays an important roll in a car because it protects passengers from external crash. The roll forming process is a continuous bending process wherein a long metal sheet is bended as it continuously passes several rolls. The characteristic of this study is that an impact beam is produced by a continuous process using a ultra high strength steel without a hardening heat treatment. A model was determined by analysing plasticity of a cross section shape considering high strength. Design parameters of the impact beam was determined by crash-analysing the model. Workpiece products were manufactured by designing dies for roll forming and setting them up in a following process line. Results of a bending test and a FEM analysis was considered and reviewed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.702-705
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• 2005

Metallic sandwich plates with Inner dimpled shell subjected to 3-point bending have been analyzed and then optimized for minimum weight. Inner dimpled shells can be easily fabricated by press or roll with high quality precision and bonded with same material skin sheets by resistance welding or adhesive bonding process. Optimized shape of inner dimple is a hemispherical shell to minimize weight without failure, including face yielding, face buckling and inner dimple buckling. It is demonstrated that bending stiffness of sandwich plate is 2 or 3 times than solid plates with same strength

• International Journal of Korean Welding Society
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• v.5 no.1
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• pp.29-34
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• 2005

Finite element analysis (FEA) and experimental studies on an elastic bending method have been performed in order to control the angular distortion at the fillet weldment for curved panel. Process parameters for the elastic bending method such as clamping span and release time were analyzed with reference to welding condition and geometric effect of the curved panel, which can minimize or prevent the angular distortion by producing a proper skin stress to the fillet weldment. The amounts of the angular distortion decrease almost in a linear manner with an increase in the skin stress. The skin stress required for non-angular distortion at the fillet weldment is strongly dependent on the plate thickness, not the heat intensity applied. The clamping span for obtaining uniform skin stress was defined as functions of the plate thickness and length of the free edge. Clamp should be removed after the fillet weldment is cooled down to room temperature for non-angular distortion. Effectiveness of the elastic bending method established was verified by its application to an actual curved panel.

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.19-24
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• 2003

Potential applications of foam-filled section are the automotive structures. A foam-filled section can be used for the front rail and firewall structures to absorb impact energy during frontal or side collision. In the case of side collision where bending is involved in the crushing mechanics, the foam filler will be significant in maintaining progressive crushing of the thin-walled structures so that more impact energy can be absorbed. In this study, the manufacturing process of closed cell aluminum alloy foam filled stainless steel tube was studied, and the various foam filled specimens including piecewise fillers were prepared, tested and discussed about the bending behaviors.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.513-517
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• 1997

Glass fiber reinforced thermoplastic composite materials have considerable promise for increased use in low cost high volum applications because of the potential for processing by solid phase forming. However, the forming characteristics of these materials have not been well known. The primary focus of this research is the investigation of the bendability of these composites and spring-back phenomena in pure bending. The materials tested contained 10, 35, and 40 percent by weight of randomly oriented glass fiber in a polypropylene matrix. The bending tests were performed at temperatures ranging form 75 ".deg. c" to 150 ".deg. c" and at punch speeds of 2.54 mm/sec and 0.0254 mm/sec. The measured bendability and spring back angle in pure bending werw compared with the predictions based on the simple analyical models. Goog agreement between experimental and analytical results was observed.esults was observed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.59-62
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• 1997

Recently, quasimolecular dynamics has been successfully used to simulate the deformation characteristic of actual size material. In quasimolecular dynamics, which is an attempt to bridge the gab between atomistic and continuum simulations, molecules are aggregated into large units, called quasimolecules, to simulate the large scale material behavior. In this paper, a numerical simulation using quasimolecular dynamics has been performed to investigate the laminar composite material fracture and crack propagation behaviors in bending process of laminar composite material which is made of fictitious materials. The simulation of the bending of laminar composite material has clarified the effects of strength of material at outer surface upon the fracture behviors of the specimen.