• Transactions of Materials Processing
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• v.23 no.7
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• pp.405-412
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• 2014

As a major type of heat exchanger, the steam generator (SG) produces steam from heat energy of a nuclear power plant reactor. The steam produced by the steam generator flows into a turbine, and plays an important role in electric power generation. The heat transfer tubes in the steam generator consist of approximately 10,000 U-shaped tubes, which perform a structural role and act as thermal boundaries. The heat transfer tubes conduct the thermal energy between the primary coolant (about $320^{\circ}C$, $157kgf/cm^2$) obtained from the reactor and the secondary coolant (about $260^{\circ}C$, $60kgf/cm^2$) as part of the secondary system. Recently, the heat transfer tubes in the steam generator of the pressurized water reactor (PWR) are primarily produced from Alloy 600 and Alloy 690 seamless tubes. As a pilot study to find process parameters for the cold U-bending process using rotary draw bending, numerical and experimental investigations were conducted to produce U-shaped tubes from long straight SUS304L seamless tubes. 3D finite element simulations were run using ABAQUS Explicit with consideration of the elastic recovery. The process parameters studied were the angular speed, the operation period and the bending angle. Experimental verifications were conducted to insure the suitability of the final U-shaped configurations with respect to both ovality and wall thickness.

• 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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• 2007.05a
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• pp.289-293
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• 2007

The effect of temperature on the forming limit diagram was investigated for AZ31B magnesium alloy sheet through the limit dome height test in the range from room temperature to $300^{\circ}C$. The formability of AZ31B sheet was improved significantly according to the increasing temperature. Also we studied the springback characteristics through the 2D draw bending test with different blank holding forces at elevated temperatures. Springback quantity was considerably reduced as temperature went up. The blank holding force in the range used, however, had little influence on springback. Experimental results obtained in this study may provide a material database for AZ31B sheet.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.304-307
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• 2008

In order to evaluate the effect of permanent softening behavior on springback prediction, 2D-draw bending simulations were compared with experiments for friction stir welded DP590 steel sheets. To account fur the nonlinear hardening behavior, the combined isotropic-kinematic hardening law was utilized with and without considering the permanent softening behavior during reverse loading. Also, the non-quadratic orthotropic yield function, Yld2000-2d, was used to describe the anisotropic initial-yielding behavior of the base sheet while anisotropic properties of the weld zone were ignored for simplicity.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.3
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• pp.68-74
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• 2001

In the drawing of large size automotive panels, elastic deflection of die components is induced by the contact force between them. The deflection is nonuniform and locally distributed, and results in nonuniform material flow. In order to arrange such a nonuniform die gap, a correcting operation, so called die spotting, is inevitable, which requires trial and error works and consuming time. A prediction of the bending deflection prior to a try-out must be useful to reduce the die spotting time. In this study, drawing process of a front fender is simulated first. and the deflection of the blank holder is calculated from the contact force imposing on th blank holder. The balance block heights ensuring a uniform deflection are optimized by the analysis and design of experiments.

• Transactions of Materials Processing
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• v.16 no.5 s.95
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• pp.364-369
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• 2007

The effect of temperature on the forming limit diagram was investigated for AZ31B magnesium alloy sheet through the limit dome height test in the range from room temperature to $300^{\circ}C$. The formability of AZ31B sheet was improved significantly according to the increasing temperature. Also we studied the springback characteristics through the 2D draw bending test with different blank holding forces at elevated temperatures. Springback quantity was considerably reduced as temperature went up. The blank holding force in the range used, however, had little influence on springback. Experimental results obtained in this study may provide a material database for AZ31B sheet.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.53-57
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• 1998

In order to investigate the effects of the variables during the stamping process upon the side wall curl behavior, experiments and finite element analyses were done using a 90 degree draw-bending test. The variables considered were the die radius, the forming speed, the restraint force, the lubrication and the sheet grade. The experiments and simulation conditions were selected according to the design of experiment (DOE) approach. The effects of the restraint force, the lubrication and the forming speed were the same for both high strength and mild steels, but the effects of the die radius on the side wall curl were dependent on the magnitude of the die radius and the sheet grade. A straight side wall was observed for both high strength and mild steels when the die radius was about 2∼3 times of the sheet thickness. It was recommended that the restraint force, the forming speed and the friction be increased in order to reduce the side wall curl.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.10a
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• pp.249-254
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• 2000

The contact forces between die components for the drawing of large size automotive panels introduce elastic deflections of the die components. Due to the deflections, the gap between blank holder and die varies locally resulting in nonuniform material flow. Such a nonuniform die gap usually requires correcting operation, so called die spotting, which is time consuming trial and error process. To reduce the die spotting time, the optimization of the blank holder bending deflection is needed. In this paper, we implemented an analysis procedure to predict the blank holder deflection. The analysis procedure and design of experiments techniques are applied to the optimization of balance block heights. The optimization results can be used as guidelines in actual die spotting process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.330-333
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• 2009

The time-dependent constitutive law was developed based on viscoelastic-plasticity to describe the time-dependent spring-back behavior of aluminum alloy 6022-T4 sheets. Besides nonlinear viscoelasticity, non-quadratic anisotropic yield function, Yld2000-2d, was used to account for the anisotropic yield behavior, while the combined isotropic-kinematic hardening law was used to represent the Bauschinger effect and transient hardening. For verification purposes, finite element simulations were performed for the draw-bending and the results were compared with experimental results.

• Transactions of Materials Processing
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• v.20 no.5
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• pp.344-349
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• 2011

Variation of contact pressure causes change of friction coefficient, which in turn changes stress distribution in the sheet being formed and final springback. In the present study, U-draw bending experiments were carried out under constant blank holding force(BHF) and different blank sizes, and finite element analysis was conducted with and without considering contact pressure effect on friction. When the BHF was sufficiently high, the degree of springback was different between constant blank holding pressure condition and that with varying blank holding pressure. Finite element analysis considering the influence of contact pressure effect on friction could explain the occurrence of springback.