• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.143-148
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• 1999

Design optimization is performed to calculated the draw-bead force for satisfying the design re-quirements. For an analysis tool a rigid-plastic finite element method with modified membrane element is adopted. response surface methodology is utilized for constructing the approximation surface for the optimum searching of draw bead force in sheet metal forming process. the algorithm developed is ap-plied to a design of the draw bead forces in a deep drawing process. The results show that the design of process parameters is applicable in complex metal forming analysis. It is also noted that the present algo-rithm enhances the stable optimum solution with small times of optimization iteration.

• 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 the Korean Society of Mechanical Engineers
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• v.16 no.4
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• pp.658-666
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• 1992

In developing computer-aided design technology for optimization of stamping die design, it has been an important issue to treat the frictional constraint acting on the blank holder surface. The main goal of this work is to establish database of draw bead restraint force and clarify friction characteristic for various automotive sheet steels, which is essential in developing friction algorithm that can be used for CAD of stamping die design. Draw bead friction tester is used to evaluate the various parameters that affect the draw restraint force and the coefficient of friction for the cold rolled and the coated sheet steels such as drawing rate, lubricant type, surface property of material, etc.

• Korea-Australia Rheology Journal
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• v.12 no.2
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• pp.107-117
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• 2000

Prediction of the product shape in sheet casting process is performed from the numerical simulation. A three-dimensional finite element method is used to investigate the flow behavior and to examine the effects of processing conditions on the sheet produced. Effects of inertia, gravity, surface tension and non-Newtonian viscosity on the thickness profile of the sheet are considered since the edge bead and the flow patterns in the chill roll region have great influence on the quality of the products. In the numerical simulation with free surface flows, the spine method is adopted to update the free surface, and the force-free boundary condition is imposed along the take-up plane to avoid severe singularity problems existing at the take-up plane. From the numerical results of steady isothermal flows of a generalized Newtonian fluid, it is shown that the draw ratio plays a major role in predicting the shape of the final sheet produced and the surface tension has considerable effect on the bead thickness ratio and the bead width fraction, while shear-thinning and/or tension-thickening viscosity affect the degree of neck-in.

• Design & Manufacturing
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• v.16 no.2
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• pp.39-45
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• 2022

Sheet Metal Forming by Press Forming Process takes a lot of time and cost from mold design to manufacturing. Therefore, all of die-makers are continuously conducting research to reduce the number of mold processes or the size of blanks to reduce costs. In the case of Forming complex shapes such as automobile component, wrinkles and cracks occur, so draw beads are used. Draw beads play an important role in suppressing the inflow of materials and minimizing the size of blanks. Factors that affect material flow include draw bead, blank holding pressure, lubricant, and surface roughness of punch and die. Most of the factors affect friction. In this study, after classifying circular beads and rectangular beads in cylindrical drawing molds using the AutoForm analysis program, the factors affecting the material inflow were considered.

• Journal of the korean Society of Automotive Engineers
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• v.15 no.3
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• pp.96-110
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• 1993

A procedure has been developed so that a die-face for stamping automobile outer panels can be design and modelled efficiently. The procedure is composed of four parts each of which corresponds to modeling major components of a die-face, i.e. tipped product, blankholder, draw beads, and step draw. The modeling techniques developed specifically for die-face design enable a designer to generate the shape of a die-face quickly with the minimum input, and the resulting models can be used in FEM analysis and NC tool path generation. This will lead to the reductions in lead time and manhours required for the design and manufacture of the stamping dies.

• Transactions of Materials Processing
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• v.9 no.3
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• pp.284-292
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• 2000

Optimization of the process parameters is carried out for process design in sheet metal forming processes. The scheme incorporates with a rigid-plastic finite element method for the deformation analysis and response surface methodology for the optimum searching of process parameters. The algorithm developed is applied to design of the draw bead force and the die radius in deep drawing processes of rectangular cups. The present algorithm shows the capability of designing process parameters which enable the prevention of the weak part of fracture during processes.

• Transactions of Materials Processing
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• v.15 no.4 s.85
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• pp.295-303
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• 2006

Optimization is carried out to determine process parameters which reduce the amount of springback and improve shape accuracy of a deep drawn product in sheet metal forming process. The study uses the amount of stress deviation along the thickness direction in the deep drawn product as an indicator of springback instead of springback simulation. The scheme incorporates with an explicit elasto-plastic finite element method for calculation of the final shape and the stress deviation The optimization method adopts the response surface method in order to seek for the optimum condition of process parameters such as the blank holding force and the draw-bead force. The present scheme is applied to design of the variable blank holding force in an U-draw bending process and the application is further extend ε d to the design of draw-bead force in a front side member formed with advanced high strength steel (AHSS) sheets of DP60. Results show that design of process parameter is well performed to decrease the stress deviation through the thickness and to reduce the amount of springback. The present analysis provides a guideline in a design stage for controlling the springback based on the finite element simulation of the complicated parts.

• Transactions of Materials Processing
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• v.14 no.2 s.74
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• pp.153-159
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• 2005

Design modification of the stamping die for the upper member of a front end module carrier is carried out in order to improve the surface quality of the final product. The small inferiority induced by wrinkling near the wall of the upper member has been inspected after the draw-forming process. The finite element analysis is pursued with the whole geometry in order to consider the complicated shape. The simulation shows that the excess metal is developed by the irregular contact of the blank the tool and it remains after the final stroke. This paper proposes two guidelines for the modification. One is to add the draw-bead near the critical region in order to increase the draw-in force. The other is to modify the tool shape such as the forming shape at the wall in order to absorb the excess metal before the final stroke. Simulation results show that the proposed guidelines both guarantee the improved surface quality.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.6
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• pp.1474-1486
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• 1990

The frictional characteristics of galvanized sheet steels(GA, EG, EGF, EGN) for automobiles were studied and compared with that of cold rolled sheet steel. A draw bead tester which simulates metal flow through a draw bead in stamping die face was used to measure coefficients of friction of galvanized sheet steels for four kinds of lubricants. Stamping formability of galvanized sheet steels for quarter outer panel was examined. The results show that stamping formability and friction characteristics were mainly influenced by the nature of zinc coating, surface roughness and micro hardness of coated layer, and proved to be very sensitive to the lubricant used.