• 소성∙가공
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• 제19권7호
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• pp.393-398
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• 2010

This paper investigates the effect of material properties on the formability of sheet metals based on the Marciniak-Kuczynski model (M-K model). The hardening behavior of the material is modeled as the Hollomon model with the strain rate effect. The yield surfaces are constructed with Hosford79 yield function. The material properties considered in this study include the R-value, the strain hardening exponent, the strain rate hardening exponent, and the crystal structure of the material. The effect of the crystal structure on formability is roughly expressed as the change of the yield surface by varying the value of the exponent in Hosford79 yield function. Results show that the R-value affects neither the magnitude nor the shape of right hand side of forming limit diagrams (FLDs). Higher strain hardening exponent and higher strain rate hardening exponent improve the formability of sheet metals because they stabilize the forming processes.

• 대한기계학회논문집
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• 제9권6호
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• pp.777-787
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• 1985

본 논문에서는 스트레치 플랜징과 슈링크 플랜징에 대하여 각 공정에서의 성 형한계를 이론적으로 구하여 이를 실험과 비교검토함으로써 효과적인 성형한계예측 방 법을 개발하는데 주안점이 있다. 스트레치 플랜징의 경우는 Wang과 Wenner의 연구에 서 얻어진 결과를 이용하여 여기에 기본적인 네킹(Necking)이론을 적용하여 성형한계 를 구하도록 한다. 한편 슈링크 플랜징의 성형한계 해석을 위해서는 Wang과 Wenner 의 스트레치 플랜징에 대한 해석방법을 응용발전시켜 응력 및 변형도등을 계산하고 주 름현상해석을 위해서 Yu 및 Johnson이 도입했던 좌굴계수(Buckling Modulus)개념을 이 용하여 미소 각변위(angular displacement)동안 플랜지부에서 생기는 굽힘에너지와 소 성변형에너지를 비교하는 판별조건을 써서 슈링크 플랜징의 성형 한계를 해석하고자 한다.아울러 각 공정에서의 이론 해석결과들을 성형실험에서 얻어진 값들과 비교 검토하도록 한다.

• 소성∙가공
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• 제9권6호
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• pp.582-589
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• 2000

In recent automotive industry, vehicle weight can be reduced by one-step forming of tailored blanks welded with two or more sheets of metal blanks. Mash seam welding shows an overlap joint, a much wider welding area, and heat affected zone(HAZ) than a laser welding. This paper deals with the forming characteristics of mash seam welded tailored blanks. Mash seam welded blanks of same or different thickness combinations were prepared, and tensile, hardness, erichsen, and dome stretching tests were done.

• 소성∙가공
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• 제9권1호
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• pp.35-42
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• 2000

In this paper, we developed the hydroforming simulator which can apply an axial compressive force and high internal pressure to bulge a tube. Experimental dtudies have been performed to investigate the effect of each parameters such as internal pressure and axial compression stroke required for the forming of circular components. Under the improper forming conditions there were two forming failures. One was the axial buckling due to excessive axial compressive load and the other was the circumferential necking fracture due to relatively high internal pressure. A safe forming zone without any failures exists between these two extreme zones. Also the condition of forming failure such as fracture is examined throughout the theoretical analysis. This paper covers a brief overview of the mechanism of hydroforming process as well as the design of die and tools.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.247-250
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• 2005

The need for improved fuel efficiency, weight reduction has motivated the automotive industry to focus on aluminum alloys as a replacement for steel-based alloy. To cope with the needs for high structural rigidity with low weight, it is forecasted that substantial amount of cast components will be replaced by tubular parts which are mainly manufactured by the extruded aluminum tubes. The extrusion process is utilized to produce tubes and hollow sections. Because there is no weld seam, the circumferential mechanical properties may be uniform and advantageous for hydroforming. However the possibility of the occurrence of a surface defect is very high, especially due to the temperature increase from forming at high pressure when it comes out of the bearing and the roughness of the bearing, which cause the surface defects such as the dies line and pick-up. And when forming a extruded aluminum tube, the free surface of the tube becomes rough with increasing plastic strain. This is well known as orange peel phenomena and has a great effect not only on the surface quality of a product but also on the forming limit. In an attempt to increase the forming limit of the tubular specimen, in the present paper, surface asperities generated during the hydroforming process are polished to eliminate the weak positions of the tube which lead to a localized necking. It is shown that the forming limit of the tube can be considerably improved by simple method of polishing the surface roughness during hydroforming. And also the extent of the crack propagation caused by dies lines generated during the extrusion process is evaluated according to the deformed shape of the tube.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 추계학술대회논문집
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• pp.269-273
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• 2003

There is a growing interest to replace the commercial steels with non-heat treated steels, which does not involve the spheroidization and quenching-tempering treatment. However, Non-heat treated steels should satisfy high strength and good formability without performing heat treatment. Therefore, it is important to investigate optimum materials showing a good combination of strength and formability after the drawing process. In this study, Dual-Phase Steels were studied as candidate materials for non-heat treated steels, which have different martensite morphologies and volume fractions obtained through heat-treatment of intercritical quenching (IcQ), intermediate quenching (ImQ) and step quenching (SQ). The mechanical properties of DP steels were measured by tension and compression tests. Also, the cold formability of three DP steels which have similar tensile strength value was investigated by estimating the deformation resistance and the forming limit. The deformation resistance which is important factor in determining die life was estimated by calculating the deformation energy. And the forming limit was estimated by measuring the critical strain revealing crack initiation at the notch tip of the specimens.

• 소성∙가공
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• 제12권4호
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• pp.364-369
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• 2003

Non-heat treated steels are attractive in the steel-wire industry since the spheroidization and quenching-tempering treatment are not involved during the processing. However, non-heat treated steels should satisfy high strength and good formability without performing heat treatment. Therefore, it is important to investigate optimum materials showing a good combination of strength and formability after the drawing process. In this study, three different steels such as dual phase steel, low-Si steel, and ultra low carbon bainitic steel were used to study their mechanical properties and the cold formability. The cold formability of three steels was investigated by estimating the deformation resistance and the forming limit. The deformation resistance was estimated by calculating the deformation energy, and the forming limit was evaluated by measuring the critical strain revealing crack initiation at the notch tip of the specimens. The results showed that deformation resistance was the lowest in the low-Si steel, and the forming limit strains of ultra low carbon bainitic steel and low-Si steel were higher than that of commercial SWRCH45F steel.

• 한국자동차공학회논문집
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• 제15권2호
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• pp.175-181
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• 2007

The objective of this study was to develop formability evaluation techniques in order to apply aluminum sandwich panel for automotive body parts. For this purpose, newly adopting formability evaluation (using limit dome height and plane strain test) was carried out in order to secure the fundamental data for the measurement of sheet metal forming and the establishment of optimum forming conditions of the aluminum sandwich panel. The results showed that there were good agreements between the old formability evaluation method and the new method which was more simplified than that of old one. From the results of these formability evaluation, the formability of sandwich panel was higher than that of aluminum alloy sheet alone which was the skin component for the sandwich panel. Also, it was found that sandwich panel could reduce the weight and could have the same flexural rigidity simultaneously when it was compared to the automotive steel sheet.

• 소성∙가공
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• 제13권1호
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• pp.84-89
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• 2004

There is a growing interest to replace the commercial steels with non-heat treated steels, which does not involve the spheroidization and quenching-tempering treatment. However, Non-heat treated steels should satisfy high strength and good formability without performing heat treatment. Therefore, it is important to investigate optimum materials showing a good combination of strength and formability after the drawing process. In this study, Dual-Phase Steels were studied as candidate materials for non-heat treated steels, which have different martensite morphologies and volume fractions obtained through heat-treatment of intercritical quenching (IcQ), intermediate quenching (ImQ) and step quenching (SQ). The mechanical properties of DP steels were measured by tension and compression tests. Also, the cold formability of three DP steels which have similar tensile strength value was investigated by estimating the deformation resistance and the forming limit. The deformation resistance which is important factor in determining die life was estimated by calculating the deformation energy. And the forming limit was estimated by measuring the critical strain revealing crack initiation at the notch tip of the specimens.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 추계학술대회 논문집
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• pp.183-185
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• 2008

Forming Limit Diagram(FLD) is a representative tool for evaluating formability of sheet metals. This paper presents a methodology to determine the FLD using Finite Element Method. For predicting the forming limits numerically. Previous methods such as using the thickness strain or the ductile fracture criterion are limited at plane strain domain. These results suggest that behavior of the void growth in sheet metals is different from real one. In contrast to previous methods, a more exact model which takes void growth into account is used. This result agrees with the experimental result qualitatively.