• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.293-295
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• 2007

The thixoforming process become important for forming automobile parts. But, the thixoforming process cannot still prevent to forming defects such as pores and shrinkage which reduce mechanical properties of automobile parts. Therefore, it is necessary to analyze the correlation between forming defects and mechanical properties. However, it is difficult to get data about relations between mechanical properties and forming defects in thixoformed aluminum alloy parts. In this study, three parts of aluminum thixoformed knuckle have been analyzed using tensile test and computer tomography(CT scan). Experimental results showed that the elongation properties of thixoformed aluminum parts were significantly dependent on size and number of forming defects.

• International Journal of Precision Engineering and Manufacturing
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• v.6 no.2
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• pp.26-33
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• 2005

In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effect of process variables such as gap height, relative gap width and die comer radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.12
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• pp.168-175
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• 2003

In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effects of process variables such as gap height, relative gap width and die corner radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.

• Transactions of Materials Processing
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• v.12 no.6
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• pp.566-571
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• 2003

The metal forming behavior and defect formation in Ti-6Al-4V tube during hot backward extrusion were investigated. Dynamic material model(DMM) including Ziegler's instability criterion was employed to predict the forming defects such as shear band, inner and/or surface cracks. This approach was coupled to the internal variables generated from FE analysis. The simulation results fur the backward extrusion were compared with the experimental observation. The chilling effect and friction indicated a great influence on the deformation mode of the tube and the formation of surface cracks. The formation of forming defects in the extruded tube was attributed to non-uniform distribution of strain, strain rate and temperatures in the extruded tubes for the given test conditions.

• Transactions of Materials Processing
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• v.18 no.5
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• pp.422-427
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• 2009

Computed tomography(CT) has been applied to measure micro-defects in the aluminum knuckle parts manufactured by the thixoforming process. 6061 aluminum alloys were used to form knuckle samples in the semi-solid temperature after the SIMA processing of billets. Tensile specimens were cut from the different locations in a thixoformed knuckle. The size and the distribution of forming defects in tensile specimens were analyzed using CT scanning and image analysis technology before tensile tests. It has been qualitatively shown that the stress-strain curves were significantly affected by the size and the distribution of forming defects although the defect sizes lie in the range of micro-meters.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.4
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• pp.110-121
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• 2009

It is essential to embed product quality in the design process to win the global competition. Many components found in many products including automobiles and electronic devices are fabricated using sheet metal forming processes. Wrinkle and fracture are two types of defects frequently found in the sheet metal forming process. Reducing such defects is a hard problem as they are affected by many uncontrollable factors. Attempts to solve the problem based on traditional deterministic optimization theories are often led to failures. Furthermore, the wrinkle and fracture are conflicting defects in such a way that reducing one defect leads to increasing the other. Hence, it is a difficult task to reduce both of them at the same time. In this research, a new design method for reducing the rates of conflicting defects under uncontrollable factors is presented by using operating window and a sequential search procedure. A new SN ratio is proposed to overcome the problems of a traditional SN ratio used in the operating window technique. The method is applied to optimizing the robust design of a sheet metal forming process. To show the effectiveness of the proposed method, a comparison is made between the traditional and the proposed methods using simulation software, applied to a design of particular sheet metal forming process problem. The results show that the proposed method always gives a more robust design that is less sensitive to noises than the traditional method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.58-61
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• 2002

A new concept of dieless sheet forming technology is proposed in this study to overcome the drawback of conventional dieless forming technology. For this purpose, dual points contact of the conventional punch system, which is a primary cause of surface defects, is replaced to single point contact using technology combined with fluid forming. It is expected that the advanced system may lead to easy displacement control of multi-punch elements, reducing surface defects, and increasing decision and forming limits. The reduced number of punch elements also saves the cost of the equipment. In addition, the new technology can be utilized for deep drawing as well as two- or three-dimensional curved surface forming, and thereby become multi-functional and multi-purpose differently from the conventional technology.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.1
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• pp.95-102
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• 2016

Wrinkle, spring-back, and fracture are major defects frequently found in the sheet metal forming process, and the reduction of such defects is difficult as they are affected by uncontrollable factors, such as variations in properties of the incoming material and process parameters. Without any countermeasures against these issues, attempts to reduce defects through optimal design methods often lead to failure. In this research, a new multi-attribute robust design methodology, based on the Mahalanobis Taguchi System (MTS), is presented for reducing the possibilities of wrinkle, spring-back, and fracture. MTS performs experimentation, based on the orthogonal array under various noise conditions, uses the SN ratio of the Mahalanobis distance as a performance metric. The proposed method is illustrated through a robust design of the sheet metal forming process of a cross member of automotive body.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.347-350
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• 2003

The metal forming behavior and defect formation in Ti-6Al-4V tube during hot backward extrusion were investigated. To predict the forming-defects such as shear band, inner cracks or surface cracks, dynamic material model(DMM) including Ziegler's instability criterion and modified Cockcroft-Latham fracture criterion(C-L model) were used. These models were coupled to the internal variables generated from FE analysis. The chilling effect and friction indicated a great influence on the deformation mode of the tube and the formation of surface cracks. The simulation results for the backward extrusion were compared with the experimental observations.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.03a
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• pp.80-91
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• 1994

This study aims detecting forming defects for the forming process of bearing rings, which is designed by an industry expert. The designed process consists of one forming operation for the outer ring and four operations for the inner ring. The thickness of the sheet used is 1.6mm, and is in between of thin sheet and bulk material. Here the rigid-plastic finite element method is applied to the analysis and design of the process without considering anisotropy of thin sheet. Thinning and folding defects are detected if the initially designed process is applied for manufacturing. so a new process is designed by referring the results of the FEM. It is confirmed that the industry expert agree the possibility of defects derived from FEM results.