• 소성∙가공
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• 제10권6호
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• pp.456-464
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• 2001

Deep drawing and ironing are tile major process today in manufacturing of aluminum alloy battery case used in cellular phone. Most of these process require multi-stage ironing following the deep drawing and redrawing processes. The practical aspects of this technology are well known and gained through extensive experiment and production know-how. However, the fundamental aspects of these processes are relatively less known. Thus, it is expected that process analysis using FEM techniques would provide additional detailed information that could be utilized to improve the process condition. This paper illustrates the application of process modeling to deep drawing and redrawing operations. To verify the simulation results, the experimental investigations were also carried out on a real industrial product. The numerical analysis by FEM shows good agreement with the experimental results in view of the deformation shape of the product. A commercially available finite element code LS-DYNA3D was used to simulate deep drawing and redrawing operations.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 춘계학술대회 논문집
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• pp.630-634
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• 1997

In this paper,we will discuss in the forming process design of the making engine pulleys for automobiles. These pulleys are required to be made by precision deep drawing process because these are to be combined with bearings and engine timing belts. These pulleys are used of cold rolled steel plates starting with the initial blanking size of 115.2mm and the initial thickness of 1.2mm. Our deep drawing process is designed the continuous 5-steps process, that is, 1'st deep drawing, 2'nd reverse redrawing, 3'rd trimming, 4'th drawing-ironing and 5'yh piercing. This process need no in-process annealing.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2001년도 추계학술대회논문집A
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• pp.459-464
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• 2001

The main object of this study is to develop a reliable FEM simulation technique for the analysis of Steel D&I Can bodymaking process using ABAQUS software. The body making process includes drawing, redrawing, 3 step ironing, doming. The newly developed FEM code in this research is based on the previous research achievement of POSCO for the drawing, redrawing and ironing process. The analysis is performed using two dimensional axisymmetric elements to analyze the punch force, the height of can, the distribution of residual stress and strain. The effect of blank thickness, gap of ironing die is also analyzed.

• 소성∙가공
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• 제19권4호
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• pp.253-262
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• 2010

For multi-stage deep drawing process including ironing operation and biaxial forming in this study, tool developments are achieved, and the developed tool sets are applied to experimental investigations. In process and tool designs, a contact condition between intermediate blank and lower die is considered as the sequential one. In this study, the material used is cold-rolled thin sheet (SPCE) with the initial thickness of 0.4mm. From the experimental approaches, several failures such as tearing, localized thickening and thinning, are observed. To solve these failures, the contact surface on the lower die is modified. As the experimental results by applying the modified lower die, it is investigated that the failures are not occurred, and the excessive deformation behavior due to the thinning and thickening effects are decreased. Furthermore, the thickness distributions on the major axis and the minor axis of each intermediate blank are investigated to be already satisfied the target (ironing) thickness, respectively. By this systematic approach, it is confirmed that the experimental results show good agreements with the designed and required configuration of each deformed and final products.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2000년도 추계학술대회논문집A
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• pp.778-782
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• 2000

Deep drawing and ironing are the major process used today in manufacturing of battery case used in cellular phone and IMT-2000 from aluminum. The same technology is utilized in manufacturing of steel or aluminum rectangular cans for components of medical instrument, portable PC, walkman and so on. Most of these processes require multi-stage ironing following the deep drawing and redrawing processes. The practical aspects of this technology are well known and gained through extensive experiment and production know-how. However, the fundamental aspects of theses processes are relatively less known. Thus, it is expected that process simulations using FEM techniques would provide additional detailed information that could be utilized to improve the process condition. This paper illustrates the application of process modeling to deep drawing and redrawing operations with the cellular phone and IMT-2000. A commercially avaliable finite element code LS-DYNA3D was used to simulate deep drawing and redrawing operations.

• Design & Manufacturing
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• 제14권3호
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• pp.37-43
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• 2020

Progressive drawing processing is one of the manufacturing processes used to mass-produce a variety of products on the industrial site. In this study, the goal is to achieve a uniform product thickness of at least 1.3mm by reducing the wall thickness of the coupler parts used in automotive air conditioning systems to within 15% using A5052-H32 materials. The progressive die was designed using Blank's law of volume invariance. Due to the characteristics of the drawing process, the material thickness in the punch R part decreases and the thickness in the die R part increases. When designing the progressive die of the coupler part, an ironing method, a push back method, and a stand-alone die pad method were applied to each process to design a mold in consideration of the drawing rate and to artificially adjust the thickness change. The suitability of the method used in die design was investigated by measuring the thickness change of forming parts for each process. In the final part, it was confirmed that the thickness measurement values of the five regions of a radial line were implemented as 1.34-1.36 mm.

• 한국정밀공학회지
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• 제30권6호
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• pp.629-637
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• 2013

In this study, a theoretical analysis method was suggested for predicting forming loads of continuous deep drawing and ironing processes (D.D.I. processes) by considering back tension and continuity equation, and FEA for D.D.I. processes was performed. Dimensions of a punch and a mold on the basis of design rules for a CNG storage vessel were applied for the analysis. To verify the suggested theoretical analysis, the results of theoretical analysis were compared with both those of FEA and experiments of previous studies. As the result of analysis, the values and tendencies of the loads predicted by the theoretical analysis were in agreement with those of FEA and the experiments. So, it is considered that the analysis suggested has reliability for predicting the forming loads of the continuous processes(deep drawing+ironing(1)+ironing(2)).

• 한국표면공학회지
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• 제30권3호
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• pp.191-201
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• 1997

Non-passivated electrolytic tinplates withour conventinal chemical treatment self-oxidize in ambient atmosphere to from yellow stain on the outermost surface during the long-term storage. The degree of yellowness of the stain increased linerly with the oxide thickness due to the interfeefence color of the $SnO_2$ Even though the thickness of the oxide layer was very thin, less than 100$\AA$ , it exerts an undesirable influence on the can-making processes, particularly the stripping behavior after ironing. Investigations were carried out on the morphologies of the coating layer, the changes in oxide thickness during successive can-making processes and the averge friction coefficients with the different oxide thinkness. These oxide layers were broken up and distributed within the bulk tin coating during the ironing process. This redistribution of the oxide layer prvented smooth pressing-aside of the tin coating layer, resulting in an increase in the ironing friction coefficient. As the friction was increased, the residual stress along the can wall thinkness(i.e., the hoop stress) was also increased. Due to both the oxibe layer accumulation, which increased the friction coefficient, and the hoop stress, can stripping efficiency without roll-back is reduced.

• 대한기계학회논문집A
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• 제37권7호
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• pp.865-873
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• 2013

CNG 압력용기의 제조를 위하여 고성능 수평식 프레스를 이용한 딥드로잉과 아이어닝의 연속공정(D.D.I. 공정)이 도입되었다. 그러나, 몇몇 D.D.I. 공정 변수들은 현장 경험에 의존하여 결정되는 문제점이 있으며, 다이의 짧은 수명 역시 고성능, 저비용의 압력용기 제조를 위하여 필수적으로 개선되어야 한다. 본 연구에서는, 공정의 신뢰성 확보 및 다이 수명 향상을 위하여 기존 관련 연구 및 현장 경험을 바탕으로 드로잉비, 다이 간의 간격, 드로잉 다이의 라운딩 반경, 아이어닝 다이의 각도를 공정변수로 결정하였다. FEA 를 이용하여 각 성형 단계에서 찢어짐과 주름이 발생하지 않는 한계 드로잉비를 결정하였고, 다이 간의 간격, 드로잉 다이의 라운딩 반경, 아이어닝 다이의 각도에 대하여 실험계획법을 이용하여 최적 공정설계를 수행하였으며, 기존 공정에 의한 결과와 비교하여 효율성을 검증하였다.

• 한국정밀공학회지
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• 제21권7호
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• pp.153-162
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• 2004

This paper describes a research work on the die design for the deep drawing ＆ ironing(D.D.I.) of high pressure gas cylinder. D.D.I die set is large-sized die used in horizontal press, which is usually composed of drawing, and ironing die. Design method of D.D.I. die set is very different from those of conventional cold forging die set.. Out diameter of the die set is fixed because of press specification and out diameter of the insert should be as small as possible for saving cost of material. In this study, D.D.I die set has been designed to consider those characteristics and the feasibility of the designed die has been verified by FE-analysis. In addition, the automated system of die design has been developed in AutoCAD R14 by formulating the applied methods to the regular rules.