• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1897-1900
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• 2005

The purpose of this study is to investigate the bending process for manufacturing of sound pipe by 3 dimension bending machine. The arbitrarily-bended pipe is widely used in a heat exchanger system. The pipe should be formed precisely for assembling of heat changer. And, spring back effect and variation of the pipe thickness should be controlled effectively. We described the change of spring back amount and thickness variation of the pipe according to the change of bending radius and bending angle by FEM analysis. The analysis is adopted the elasic-plastic analysis and contact analysis on MARC software.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.359-362
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• 2003

The bending phenomenon has been known to be occurred by the different of velocity at the die exit. The difference of velocity at the die exit section can be obtained by the different velocity of billets through the multi-hole container and by the cohesion of billet inside the porthole die chamber. The bending phenomenon can be controlled by the different hole diameter. The experiments using aluminium material for the curved tube product had been done. The results of the experiment show that the curved tube product can be formed by the extru-bending process without the defects such as the distortion of section and the thickness change of the wall of tube and the folding and wrinkling. It is known that the welding and extruding of each billet has done simultaneously although the curved tube is extruded with four billets.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.11a
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• pp.63-70
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• 2002

The purpose of the present study is to propose a new way of manufacturing curved metal tubes with arbitrary sections and way of eliminating the conventional bending defects such as thinning and thickening, in the wall of tube, distortion of the section, and wrinkling and folding on the surface by the extrusion bending process that can extrude and weld together one or more billets inside dies cavity, and can bend them during extrusion due to the gradient of extrusion velocities controlled by the eccentricity of the cavity sections between the entrance and the exit of the eccentric conical extrusion bending dies and conical plug, or by the relative size of the holes of multi-hole container, or by the relative moving velocity of multi-punches.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.244-247
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• 2009

Hydroformed parts have higher dimensional accuracy, structural strength, and dimensional repeatability. Particularly in the automotive industry, manufacturing of parts with complex shapes from tubular materials sometimes requires one or more pre-forming operations such as bending before the hydroforming process. The pre-bending process is an important factor for successful hydroforming in the case where the perimeter of the blank is nearly the same as that of final product. The bendability of a tube depends on the parameters such as the bending radius, variation of the diameter, thickness, hardness. This study shows the analysis of bending through the stainless steel tubes bent to rotary draw bending machine.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.285-288
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• 2007

In the recent years the using of low-density material such as high-strength Al alloy on the various industries is becoming light-weight. High strength and hollow Al alloy is good material for stiffness and recycling. Therefore the advanced manufacturing technology with Al alloy is continuously required in many industrial fields. In this study simplified hallow rectangular section of Al alloy is analyzed by FE analysis. Bending stress is affected punching and rotating of wing-die. The analysis of press bending is preformed at first. The elastic recovery value of component and stress distribution acting from the result of the bending angle of three types were obtained. The designed precesses were analyzed by the commercial FE code, Deform-3D. Forming dies for each process were designed and prototypes were manufactured by the verified forming process. Some of the important features of design parameters in the press bending were reviewed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.285-288
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• 2003

The bending phenomenon during extruding one product using four billets can be obtain by the difference of hole diameters in the multi-hole container. The difference of hole diameter caused the difference of billet amount inserted in the die cavity. As results, it can bend during extruding products by the different amount of two billets and by the cohesion of billets in the porthole dies cavity. And the bending curvature can be controlled by the size of holes and billets. The experiments using aluminium material had been done for the rectangular and square curved tube product. The results of the experiment show that the curved aluminum tube product can be bended by the extru-bending process without the defects such as the distortion of section and the thickness change of the wall of tube and the folding and wrinkling. The curvature of product is affected by shape of cross section and the difference of billet diameters. It is known that the welding and extruding and bending can be done simultaneously in the die cavity when a rectangular hollow curved tube would be extruded by porthole dies using four different size billets made of aluminum material.

• Transactions of Materials Processing
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• v.12 no.5
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• pp.440-448
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• 2003

Sheet or plate bending is one of the most important industrial metal forming processes. Considerable attention has been focused on gaining a better understanding of bending characteristics. One of defaults in bending process is the springback. In this study, the springback characteristics of tailor-welded strips in U-bending process was investigated. Furthermore, effect of the process variables such as the geometry of the tools, thickness combination of workpiece, and welding prcoessing on springback were experimentally clarified. First, tailor-welded strips are joined by the laser welding process and consisted of two types of thickness combinations of the SCPl sheet, $0.8t{\times}1.2t$ and $0.8t{\times}1.6t$ to investigate the effect of different thickness combination on the springback. Secondly, two different directionly welded strips, one was welded along the centerline of the strip-width and the other was along the centerline of strip-length, were adopted to compare the effects of the location of weld line on the springback. Some cases of the experimental results were compared to the results simulated by using a commercial FEM code, PAM-STAMP and the theoretical results using the springback formula as well.

• Design & Manufacturing
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• v.15 no.3
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• pp.19-25
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• 2021

The bending process of a press die is to bend a flat blank to the required angle. There are V-bending, U-bending, Z-bending, O-bending etc. for bending processing, and the basic principle of calculating the unfolding length of die processing is used as the neutral plane length. Since the constant of the length value of the neutral surface is different depending on the type of bending, it is impossible to accurately calculate it. In particular, Z-bending processing is performed twice, and it is set on the upper and lower surfaces of the blank, and bending processing occurs at the same time as the upward and downward bending, and the elongation of the material occurs and the material increases. It is not possible to check with the calculated value, and it occurs in many cases where the mold is modified after start-up. This study aims to minimize die modification by developing a formula to calculate the development length of Z-bend.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1082-1086
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• 2004

Since the sheet forming of Mg alloy has many difficulties due to the low formability, many forming conditions need to be selected properly. Especially, the process variables should be investigated to increase the formability, such as, forming temperature. In this paper, the effects of forming process variables has been investigated using the bending and deep drawing process. A simple U-bending designed for mobile part could be formed in room temperature and springback amounts are surveyed. On the other hand, square cup part couldn't be formed in room temperature due to the low formability. Therefore, the effects of forming temperature are investigated in deep drawing process for square cup part. As a experimental and FEM results, the optimum forming temperature is presence and formability in a higher temperature is less than that of lower temperature. Above experimental results are compared with the FEM analysis and well coincided with the experimental results. Therefore, more detail investigations could be progressed to select more appropriate process conditions by the FEA.

• Transactions of Materials Processing
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• v.14 no.6 s.78
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• pp.547-552
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• 2005

In general, the sheet metal and die are described by finite elements for the simulation of the metal forming processes. Because the characteristics as continuum of the sheet metal are represented with triangles and rectangles, the errors occur inevitably in finite element analysis. Many contact schemes to describe the deformation modes exactly have been introduced in order to decrease these errors. In this study, a scheme for continuous contact treatment is proposed in order to consider the realistic behavior of contact phenomena during the forming process. The discrete mesh causes stepwise propagation of contact nodes of the sheet even though the contact region of the real forming process is altered very smoothly. It gives rise to convergence problem in case that the process, for example bending process, is sensitive to the contact between the sheet and the tools. The analysis of the unconstrained cylindrical bending process without blank holder is also presented in order to investigate the effect of the proposed algorithm.