• Design & Manufacturing
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• v.14 no.1
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• pp.63-68
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• 2020

Ultra-high brightness and thin displays need to optical micro-patterns which can uniformly diffuse the lights and low loss. The micro random patterns have characteristics to rise the optical efficiency such as light extraction, uniform diffusion. For this reason, various fabrication processes are studied for random patterns. In this study, the micro random patterns were machined by diamond turning which used a controlled cutting tool path with random cutting depth. The machined patterns had random shape and directionality along the circumferential direction. The average width and length of machined random pattern according to rotation radius were 40.13㎛~55.51㎛ and 37.25㎛~59.49㎛, and these results were compared with the designed result. Also, the machining error according to rotation radius in diamond turning using randomly controlled cutting depth was discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.35-38
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• 1999

Tube bending is an important factor of the hydroforming processes. The tube must be bent to the approximate centerline of the finished part prior to hydroforming to enable the tube to be placed in the die cavity. This paper presents the simulation results in prebending process by a rotary bending machne and a bend die that is used to form an automotive part a tie bar, Prebending simulation is carried out to obtain the shape change of cross section and thinning in bending process. To avoid occurring wrinkle in compressive zone during bending process a wiper die included,. A parametric study is carried out to obtain the effect of the forming parameters such as a bend radius and tube thickness

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.65-71
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• 1997

Computer simulations and test trials are carried out to get the optimal conditions about the stamping die design of the tailor laser welded automotive door inner. Firstly, the stamping process including gravity deflection, bead calibration, binder wrap, forming and spring back, are analyzed by the computer simulation. The results of simulation shows good correspondance with those of test trial under the same conditions. The variables of parametric study which will be investigated in the simulation and test trials, are determined form the results of the first run. The formability under the various conditions is evaluated, which are the initial postion of blank, blank holding force, corner radius and the shape of drawbead. Finally, well controled sound product without fracture, wrinkling and excessive weldline movement is obtained.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.3
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• pp.299-305
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• 2010

In general, the flexible forming die that has been used in the flexible forming process has the identical punch size; hence, its flexibility is relatively low because the range of allowable curvature radii is limited due to the uniform punch tip radius. Hence, a conceptual design of a sectional flexible die is presented for enhancing the flexibility of the forming process. Two punches of different sizes are used to configure the arbitrary forming surface. For a forming region with a relatively large curvature radius, a large punch array block is used; on the other hand, for the forming regions with small curvature radii, a small punch block is used. The cross-sectional profiles are compared with the target shape for evaluating the effectiveness of the process. Consequently, it is confirmed that the sectional flexible die can be used along with a combination of punch blocks of different sizes for manufacturing objective surfaces of complex shapes.

• Transactions of Materials Processing
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• v.27 no.4
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• pp.236-243
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• 2018

A multi-point forming die (MPFD), which has been used for producing curved plates, is capable of forming various curved plates with just one MPFD. However, in real industries, an MPFD is difficult to be adopted since the structural properties, punch strength, elastic recovery correction and dimensional accuracy become problems. In order to overcome these problems, the hot multi-point forming die (HMPFD) was proposed in this study. This HMPFD commonly provide more less spring-back and forming load than conventional MPFD. Nevertheless, this process is very difficult to form the curved plate, because the final curved shape of the plate depends on many process variables such as the punch/nozzle arrangement (height and distance), the radius of punch, contact conditions between plate and punch. In this study, the forming characteristics of HMPFD and conventional MPFD are compared with each other through the finite element analysis.

• Transactions of Materials Processing
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• v.7 no.4
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• pp.382-392
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• 1998

Computer simulations and test trials were carried out to obtain the optimal stamping conditions of the die design of the laser welded automotive body. The stamping process including gravity deflection bead calibration binder wrap, forming and spring back was simulated and compared with the results obtained from test trials. The production variables were determined from a preliminary operation and they were investigated in the simulation and the test trials. The formability was tested under the various conditions, such as the initial position of blank, blank holding force, corner radius and the shape of drawbead. Sound products without fracture, wrinkling and excessive weldline movement were produced by applying results obtained this investigation.

• Transactions of Materials Processing
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• v.21 no.8
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• pp.485-492
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• 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
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• v.16 no.2 s.92
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• pp.107-112
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• 2007

In this study, the mechanical joining process for double sheet metals was investigated by using physical modeling method. Process parameters of mechanical joining such as friction coefficient, drawing depth, pouch radius, die radius and material thickness are preliminarily analyzed by finite element method. Referring to the finite element analysis results mechanical joining system is designed on the basis of physical similarities. From the physical modeling test, the effect of process parameters on the deformation for the mechanical joining are experimentally investigated and optimized joining shape that can provide strong joining strength is obtained.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.06a
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• pp.55-60
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• 2006

Draw-bead is applied to control the material flow in a stamping process and improve the product quality by controlling the draw-bead restraining force (DBRF). Actual die design depends mostly on the trial-and-error method without calculating the optimum DBRF. Die design with the predicted value of DBRF can be utilized at the tryout stage effectively reducing the cost of the product development. For the prediction of DBRF, a simulation-based prediction model of the circular draw-bead is developed using the Box-Behnken design with selected shape parameters such as the bead height, the shoulder radius and the sheet thickness. The value of DBRF obtained from each design case by analysis is approximated by a second order regression equation. This equation can be utilized to the calculation of the restraining force and the determination of the draw-bead shape as a prediction model. For the evaluation of the prediction model, the optimum design of DBRF in sheet metal forming is carried out using response surface methodology. The suitable type of the draw-bead is suggested based on the optimum values of DBRF. The prediction model of the circular draw-bead proposes the design method of the draw-bead shape. The present procedure provides a guideline in the tool design stage for sheet metal forming to reduce the cost of the product development.

• Transactions of Materials Processing
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• v.21 no.3
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• pp.202-206
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• 2012

Marking is a process that engraves letters or a pattern onto the surface of sheet metal. During marking, it is important to set the proper working conditions for clarity of the letters. In this study a simple case for forming circular protrusions by half-piercing and embossing was initially attempted to determine the working conditions which gave good results with respect to shape accuracy. Corner-radius and flatness of circular protrusions made under several experimental conditions were measured and compared. It is shown that the precision of protrusions by half-piercing is superior to that of embossing, and the clearance between punch and die exerts a strong influence on the shape accuracy rather than the penetration percentage into the thickness of the sheet metal. The marking dies for "SNUT" letters, as an example, by applying the above results were manufactured with four different clearances. The working variables for the experiment were clearance and marking depth. For the very shallow depth of 0.1mm the letters were not clearly read. Letters marked under other conditions were easily distinguished with increasing marking depth. It was confirmed that the half-piercing technique with proper values of the working variables gives good quality for the marking of sheet metal.