• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.4
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• pp.121-126
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• 2011

An accumulator placed on the refrigerant cycle pipe lines is a part to relax fluctuations of pressure within the pipe lines and stabilize refrigerants flowed into pipe. The accumulator has been mainly manufactured by the process of tube spinning using CNC(Computer Numerical Control) lathe. However, this process has the defects which are low productivity per hour and high cost. For that reason, tube end-forming using roll die is actively being developed, recently. The purpose of this study is to develope the tube end-forming process using roll die in order to manufacture the accumulator for the refrigeration pipe lines. First, the process design of tube end-forming was performed based on specification of product, and then was verified with FE analysis. Also, the effects of friction coefficient and revolution speed of roll die on forming load were investigated. The analytical results were applied in the final process design of tube end-forming. Finally, tube end-forming test was carried out to verify the validity of the FE analysis and the process design.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.53-57
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• 2002

Brake tube is considered one of the most important parts in automobile. The shape of brake tube-end has a great influence on the function of brake, and the quality and productivity of brake tube have relation to die design. The forming process of brake tube-end is peformed by hydraulic press forming machine. In this paper, the forming processes of tube-end for automobile is analyzed and designed to make the optimal form of brake tube-end. Also, finite element analysis has been carried out using DEFORM-3D$\^$TM/ to predict the optimal shape of brake tube-end and the results obtained showed the optimal length between punch and chuck is 1.0 ∼ 1.2mm. The shape of tube-end is in good agreement with the finite element simulations and the experimental results.

• Journal of Power System Engineering
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• v.6 no.3
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• pp.31-35
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• 2002

Brake tube is considered one of the most important parts in automobile. The shape of brake tube end has a great influence on the function of brake, and the quality and productivity of brake tube have relation to die design. The forming process of brake tube end is performed by hydraulic press forming machine. In this paper, the forming processes of tube end for automobile is analyzed and designed to make the optimal form of brake tube end. Also, finite element analysis has been carried out using $DEFORM^{TM}% 3D to predict the optimal shape of brake tube end and the results obtained showed the optimal length between punch and chuck is $1.0{\sim}1.2mm$. The shape of tube end is in good agreement with the finite element simulations and the experimental results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.155-160
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• 2008

End part of the brake tube formed with the shape of snake head is important for the braking of automobile in safety because it has to prevent crack, fracture and defects occurred during the forming process. Especially, the shape of tube end has influence on the ability of brake. Based on the procedure of process design, in this paper, the forming operation is done by finite element method and the design variables are analyzed by Taguchi method. Design variables such as the outer angle of tube end with the shape of snake head(A), the inner angle to make a hole at tube end with the shape of snake head(B) and the forming distance at tube end(C) are used. Optimization of design variables is performed to minimize the damage factor of the tube end occurred during the forming process. The value of damage factor of 0.327 was obtained under the optimal condition like $A=114^{\circ},\;B=80^{\circ}$ and C=5.3mm, respectively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.21-24
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• 2003

In hot forming process of the backward end-bulkhead of a pressure hull, the blank diameter and the tool clearance are the critical factors which influence wrinkling defect, forming load and shape completeness of the product. Two F.E.A softwares with the elasto-plastic material model and rigid plastic model were utilized to predict the occurrence of wrinkling defect. Tool clearance was determined by considering the increase of blank thickness, die strength and the stretching effect. Heat treatment condition after the hot forming to recover the original properties of the material was estabilished by specimen-based heat treating experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.54-58
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• 2001

In recent years, hydroforming technology has been one of the most important technology in automotive industry in the points of weight saving, cost reduction and qualify improvement. However, compared with traditional metal forming technology, hydroforming has much fewer information in experience and empirical knowledge. But we don't have my sufficient time and money to produce hydroforming products using real blank directly Therefore Simulation is essential in hydrofonrung technology development. In this paper, we simulate the side member as the tubular hydroforming technology. The manufacturing process of side member' consists of pre_bending, pre_forming, and hydroforming of a thin tube. Variables such as internal pressure, end feeding, and tool geometry are optimized to improve the forming safety. And we simulate side member according to several lubricant conditions. from those simulations, we find that strain distributions can be reduced well by internal pressure and end feeding control, and lubrication is the most important thing in hydroforming process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.393-394
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• 2009

• Journal of Ocean Engineering and Technology
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• v.13 no.4 s.35
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• pp.75-81
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• 1999

Roll forming process is simulated with a commercial FEM code LS-DYNA. The rolls are treated as rigid bodies rotating with a constant angular velocity. The strip and the rolls are modeled with 4-node plate elements. It is assumed that the nodes along the front end of the strip move along paths given by sine functions. It is found that the analysis can be applied to the optimal design of forming rolls. With these analyses, it is expected that forming defects can be avoided and process development efforts can be reduced.

• Design & Manufacturing
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• v.10 no.2
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• pp.44-49
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• 2016

The roll forming produces mass products using the continuous production process. Also we need the process that continuous long material or goods cutting into a desired length. Our study uses 3-D driving cutter and roll forming material as SPCC to investigate this. When we cut the material using the process of roll forming, the shear resistance is raised at the cutting punch's edge. The result is remained the trouble about burr and progressive deformation on the material. This study shows the method minimizing the above trouble. The material of punch was considering heat generated on the continuous production process. So we used the type of STD 61 for the material of punch and had the vacuum heat treatment for the surface hardness of HRC 53. The structure of the mold is designed with forming a double cam die at the upper punch and the both sides of central core. We conducted the experiment three times. In the result when had to make V-groove within the angle between 105 and 110 on the punch front end, we could get the minimum shear resistance on the punch front end. Also with the same condition we minimizes the material jams in the continuous production process.

• Proceedings of the Korea Technical Association of the Pulp and Paper Industry Conference
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• 1999.11a
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• pp.92-96
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• 1999

지합에 영향을 미치는 초지공정의 인자로는 펄프섬유의 특성 및 이의 처리조건, Wet-End Chemistry 그리고 Forming부에서의 탈수 Element의 조건 등을 들 수 있다. 본보고는 지합개선을 위하여 Forming부의 탈수에 의한 지료 교란에 초점을 맞추어 초지기 Wire Part의 지료의 움직임과 현 상황을 측정·분석하여 문제점 및 개선점을 도출한 후, 현 초지 조건에 가장 적합하도록 Wire상의 탈수소자를 조정하였다. 그결과 Forming부에서의 Turbulence를 지속적으로 발생시키도록 탈수곡선을 제조정함으로서 조정 전 대비 괄목할 만한 지합 향상효과를 얻어 이를 보고하고자 한다.