• Journal of the Korean Society for Precision Engineering
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• v.28 no.4
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• pp.496-504
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• 2011

This paper introduces a CAE-based design procedure in the press forming process for the fabrication of sheet metal parts used in proto-cars. The finite element analysis reveals formability problems during the forming process of a floor member and a front cross member that constitute a rear floor assembly. The study proposes the modification of the initial blank shape or intermediate trimming of the product to prevent failure during forming. It is confirmed by the tryout process as well as the finite element analysis that sound prototype can be obtained with the modified design. The finite element analysis result also provides fairly good prediction of springback amounts used for the post-compensation of the product.

• Design & Manufacturing
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• v.7 no.1
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• pp.28-33
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• 2013

During the cold forming, due to high working pressure acting on the die surface, failure mechanics must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The mechanisms of wear are consisted of adhesion, abrasion, erosion and so on. Die wear affects the tolerances of formed parts, metal flow, and costs of process. The only way to control these failures is to develop a prediction method on die wear suitable in the design state in order to optimize the process. The wear system is used to analyse 'operating variables' and 'system structure'. In this study, with AISI D2, AISI 1020, AISI 304SS materials, a series of the wear experiments of pin-on-disk type to obtain the wear coefficients from Archard's wear model and the upsetting processes are carried out to observe the wear phenomenon during the cold forming process. The analysis of upsetting processes are performed by the rigid-plastic finite element method. The result of the analysis is used to investigate the die wear the processes, and the analysis simulated die wear profiles are compared with the experimental measured die wear profiles.

• Design & Manufacturing
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• v.16 no.2
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• pp.1-6
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• 2022

As environmental regulations are strengthened, automobile manufacturers continuously research lightweight structures based on carbon fiber reinforced plastic (CFRP). However, it is difficult to see the effect of strength reinforcement when using a single CFRP material. To improve this, a hybrid laminate in which CFRP is mixed with the existing body structural steel was proposed. In this paper, CFRP patch reinforcement is applied to each compression/tensile action surface of a 22MnB5 metal sheet, and it was evaluated through a 3-point bending experiment. Progressive failure was observed in similar deflection on bending deformation to each one-sided reinforced specimen. After progressive failure, the tensile reinforced specimen was confirmed to separate the damaged CFRP patch and 22MnB5 sheet from the center of the flexure. The compression reinforced specimen didn't separate that CFRP patch and 22MnB5, and the strength reinforcement behavior was confirmed. In the compression reinforced specimen, damaged CFRP patches were observed at the center of flexure during bending deformation. As a result of checking the specimen of the compression reinforcement specimen with an optical microscope, It is confirmed that the damaged CFRP patch and the reinforced CFRP patch overlapped, resulting in a concentrated load. Through the experimental results, the 22MnB5 strength reinforcement characteristics according to the reinforcement position of the CFRP patch were confirmed.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.128-133
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• 2004

This study has been focused on the development of shear forming process of grid for lead-acid battery. The grid plays an important role in the flow of electricity because the grid is a skeleton of the pasted plate. Therefore, it must be of the highest quality to prevent plate failures and then, battery failure, and ensure the best battery performance possible. The finite element analysis of the shear forming process is carried out and the result is compared with the experimental data. The influence of the numerical parameters such as clearance, velocity of punch and critical damage value on the simulation results turns out to be very considerable.

• Design & Manufacturing
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• v.15 no.4
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• pp.51-56
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• 2021

Piercing is the process of shearing a circular hole in sheet metal, whose high shear force makes it difficult to secure the durability of tools. In addition, uneven clearance between tools due to poor alignment of the piercing punch causes accelerated die wear and breakage of the tool. This study reviewed the feasibility of in-situ determining alignment failure during the piercing process by analyzing the signal deviation of a bolt-type piezo sensor installed inside the tool whose alignment level was controlled. Finite element analysis was performed to select the optimal sensor location on the piercing tool for sensitive detection of process signals. A well-aligned piercing process results in uniform deformation in the circumferential direction, and shearing is completed at a stroke similar to the sheet thickness. Afterward, a sharp decrease in shear load is observed. The misaligned piecing punch leads to a gradual decrease in the load after the maximum shear load. This gradual decrease is due to the progressive shear deformation that proceeds in the circumferential direction after the initial crack occurs at the narrow clearance site. Therefore, analyzing the stroke at which the maximum shear load occurs and the load reduction rate after that could detect the misalignment of the piercing punch in real-time.

• Advances in aircraft and spacecraft science
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• v.3 no.1
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• pp.61-75
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• 2016

Climate changes brought on by human interventions have proved to be more devastating than predicted during the recent decades. Recognition of seriousness of the situation has led regulatory organisations to impose strict targets on allowable carbon dioxide emissions from automotive vehicles. As a possible solution, it has been proposed that Fibre Metal Laminate (FML) system is used to reduce the weight of future vehicles. To facilitate this investigation, FML based on steel and self-reinforced polypropylene was stamp formed into dome shapes under different blank holder forces (BHFs) at room temperature and its forming behaviour analysed. An open-die configuration was used in a hydraulic press so that a 3D photogrammetric measurement system (ARAMIS) could capture real-time surface strains. This paper presents findings on strain evolutions at different points along and at $45^{\circ}$ to fibre directions of circular FML blank, through various stages of forming. It was found initiation and rate of deformation varied with distance from the pole, that the mode of deformations range from biaxial stretching at the pole to drawing towards flange region, at decreasing magnitudes away from the pole in general. More uniform strain distribution was observed for the FML compared to that of plain steel and the most significant effects of BHF were its influence on forming depth and level of strain reached before failure.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.254-257
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• 2006

In the last few years, ductile fracture criteria based on various hypotheses have been developed and utilized with FEM to predict forming failure. The accurate deformation analysis by the FEM and the decision of damage parameters are the most important factors in these approaches. In this paper, several conventional integral forms of fracture criteria were introduced and the test method to determine damage parameters by using notched specimen was suggested. Based on the results, damage parameters obtained under the different stress system (tensile and compression) are compared and analyzed.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.11
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• pp.106-113
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• 1996

Using stainless steel as the cold forged parts especially the outer parts of automobile is gradually increasing because it can bear up against the erosion and the wear. During cold forging of the stainless steel the working pressure acting on die surface are very high therefore the wear on die surface can be greatly increased. In cold forging processes, die failure must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The die wear affects the tolerances of forged parts, metal flow and costs of processes etc. The only way to to control these failures is to develop methods which allow prediction of the die wear and which are suited to be used in the desing stage in order to optimize the process. In this paper, the rigid-plastic finite element method was combined with the wear prediction routine and then the forward extrusion process using stainless steel was analysed simultaneously. To minimize the die wear the FPS algorithm was applied and the optimal conditions of die configuration are suggested.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2004.10a
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• pp.534-541
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• 2004

The modeling of crack initiation and propagation is very important for the failure analysis of concrete. The cracking process in concrete is quite different from that of other materials, such as metal and glass, in that it is not a sudden onset of new free surface but a continuous forming and connecting of microcracks. The failure process of concrete by cracking causes irreversible deformations and stiffness degradation. Those phenomenon can be modeled using plasticity and damage theory in macroscopic aspect. In this study, a plastic-damage model based on homogenized crack model considering velocity discontinuity and damage variable which is a function of plastic strain is proposed for fracture analysis of concrete. Finally, the plastic-damage model is verified with experimental data.

• Journal of Industrial Technology
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• v.31 no.A
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• pp.45-51
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• 2011

A study has been made on defects which are formed in manufacturing processes of engine bearing and also on fatigue crack growth behavior in each step of bearing metal manufacturing. After the first step (sinter brass powder on steel plate ; Series A) many voids are made on brass surface and its size is decreased at the second step (rolling process of sintered plate ; Series B). After the third step (re-sintering step of brass powder and rolling ; Series C) the number of voids is decreased and its type shows line. The time of fatigue crack initiation and the growth rate of fatigue crack are in order of Series A, Series B, Series C. These reasons are that void fosters the crack initiation and growth, and residual stress made by rolling process affects on the crack growth rate in Series B, C. In forming and machining processes by use of final bearing metal, crack was observed at internal corner of flange and peeling off was observed at interface between steel and brass. Owing to the above crack and peeling off, it is considered that there is a possibility of fatigue fracture during the application time.