• 제목/요약/키워드: Forming Roll

검색결과 222건 처리시간 0.023초

샌드위치판재를 적용한 자동차 범퍼 빔 개발 (Development of Manufacturing Technology for Bumper Back Beam with Sandwich Plate)

  • 김동규;유정수;박상언;이규현;김광희;이문용
    • 한국소성가공학회:학술대회논문집
    • /
    • 한국소성가공학회 2009년도 춘계학술대회 논문집
    • /
    • pp.199-202
    • /
    • 2009
  • In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. Tn this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal Front Bumper Beam manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle. And also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

  • PDF

실시간 공정데이터 기반의 스마트 롤포밍에 관한 연구 (Smart Roll Forming Based on Real-Time Process Data)

  • 손재환;조동현;김철홍
    • 한국기계가공학회지
    • /
    • 제17권5호
    • /
    • pp.45-51
    • /
    • 2018
  • Roll forming refers to the production of long plate-molded products, such as panels, pipes, tubes, channels, and frames, by continuously causing the bending deformation to thin plates using rotating rolls. As the roll forming method has advantages in terms of mass production because of its excellent productivity, the size of the roll forming industry has been continuously increasing and the roll forming method is increasingly being used in diverse industrial fields as a very important processing method. Furthermore, as the roll forming method mainly depends on the continuous bending deformation of the plate materials, the time and the cost of the heterogeneous materials developed in the process are relatively large when considered from the viewpoint of plastic working because many processes are continuously implemented. The existing studies on roll forming manufacturing have reported the loss of large amounts of time and materials when the raw materials or product types were changed; further, they have stated that the use of this method can hardly guarantee the uniformity of the formed shapes and the consistency in terms of size and cannot detect all the defects occurring during the mass production and related to the dimensions. Therefore, in this research, a real-time process data-based smart roll forming method that can be applied to multiple products was studied. As a result, a roll forming system was implemented that remembers and automatically sets the changes in the finely adjusted values of the supplied quantities of individual heterogeneous materials so that the equipment setting changing time for heterogeneous material replacements or changes in the products being produced can be shortened. It also secures the uniformity of the products so that more competitive and precise slide-rail products can be mass-produced with improvements in the quality, price, and productivity of the products.

좌우 대칭 모자형 단면이 길이 방향으로 선형적으로 변하는 롤 포밍 공정의 개발 (Development of a Roll-Forming Process of Linearly Variable Symmetric Hat-type Cross-section)

  • 김광희;윤문철
    • 한국기계가공학회지
    • /
    • 제14권4호
    • /
    • pp.118-125
    • /
    • 2015
  • The roll-forming process is a highly productive incremental forming process and is suitable for manufacturing thin, high-strength steel products. Recently, this process has been considered one of the most productive processes in manufacturing high-strength steel automotive structural parts. However, it is very difficult to develop the roll-forming process when the cross-sectional shape of the product changes in the longitudinal direction. In this study, a roll-forming process for manufacturing high-strength steel automotive parts with a linearly variable symmetric hat-type cross-section was developed. The forming rolls were designed by the 3D CAD system, CATIA. Additionally, the designed forming rolls were modified by the simulation through the 3D elastic-plastic finite element analysis software, MARC. The results of the finite element analysis show that the final roll-forming roll can successfully produce the desired high-strength steel automotive part with a variable cross-section.

미세 딤플 내부구조재 제작을 위한 롤 성형기술 연구 (A Study on Roll Forming Technology for Inner Structure Plate with Micro Dimple)

  • 제태진;김형종;김보환;허병우;성대용;양동열;최두선
    • 소성∙가공
    • /
    • 제15권4호
    • /
    • pp.326-332
    • /
    • 2006
  • Sandwich structures, which are composed of a thick core between two faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Depending on the sheets by a rolling process, which is a more efficient and economical approach compared to other types of processes, has become an increasingly important subject of study. In this paper, we made a roll forming machine which progressive forming possible and force measurement for a roll forming of the sheet metal forming. And we designed a roll molding that arrayed of embossing size 3mm in diameter fabricate micro dimple inner structure plate. We carried out forming experiment such as array change and thickness to sts304 sheet. Ultimately, this research developed inner structure plate of high stiffness.

페일 세이프 코드의 성형가공 롤 포밍 머신의 설계 (Design of Roll Forming Machine for Fail Safe Chord Forming Process)

  • 정원재;박민혁;최진규;남광식;조상;이재형;이석순
    • 한국기계가공학회지
    • /
    • 제13권4호
    • /
    • pp.44-49
    • /
    • 2014
  • Roll forming technology has a problem in that it depends only on experience without accurate data in the actual field. To solve this problem, it is necessary to procure accurate data during the roll forming process. To this end, we determined the operating force and the material thickness by implementing several changes to those variables during an experiment. This study compares the FEA results and experimental results. Experimental results were used for the basic data of the design. The FEA results show that the roll forming machine is operating accurately and safely. And, a comparison of the results shows that the design of the automatic roll forming machine is operating in the right way. This design of an automatic roll forming machine will be helpful for many areas of the industry.

마이크로 박판 미세 패턴 성형공정에 대한 해석적 연구 (On the analysis of micro pattern forming on the thin sheet metal)

  • 차성훈;신명수;김종호;김종봉;송정한;이혜진
    • 한국소성가공학회:학술대회논문집
    • /
    • 한국소성가공학회 2009년도 추계학술대회 논문집
    • /
    • pp.53-56
    • /
    • 2009
  • Roll forming process is one of important metal processing technology because the process is simple and economical. These days, roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate for productivity. However, it is difficult to apply to the forming of micro scale or sub-micro scale pattern. In this study, the roll forming processing for the micro scale is designed and analyzed. In this study, the forming of micro pattern for solar cell plate by incremental roll forming process is analyzed. The solar cell plate may have thousands of patterns, and the analysis of forming considering all the patterns is impossible due to the computational costs. In this study, analyses are carried out for various numbers of patterns and the results are compared. It is shown that the analyses results with four row patterns and twelve row patterns are same. So, it is considered that the analysis can be carried out for only four rows of pattern for the design of incremental roll forming process. Also experiment is carried out process that is designed through simulation.

  • PDF

마이크로 박판 미세 패턴 성형공정에 대한 해석 효율성 연구 (On the effective analysis method of micro pattern forming on the thin sheet metal)

  • 차성훈;신명수;김종호;김종봉;이혜진;송정한
    • 한국소성가공학회:학술대회논문집
    • /
    • 한국소성가공학회 2009년도 춘계학술대회 논문집
    • /
    • pp.56-59
    • /
    • 2009
  • Roll forming process is one of important metal processing technology because the process is simple and economical. These days, roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate for productivity. However, it is difficult to apply to the forming of micro scale or sub-micro scale pattern. In this study, the roll forming processing for the micro scale is designed and analyzed. In this study, the forming of micro pattern for solar cell plate by incremental roll forming process is analyzed. The solar cell plate may have thousands of patterns, and the analysis of forming considering all the patterns is impossible due to the computational costs. In this study, analyses are carried out for various numbers of patterns and the results are compared. It is shown that the analyses results with four row patterns and twelve row patterns are same. So, it is considered that the analysis can be carried out for only four rows of pattern for the design of incremental roll forming process.

  • PDF

롤 포밍 공법을 이용한 고강도 차체 부품 제작 기술 개발 (Development of Manufacturing Technology for Center Floor Cross Member with Roll Forming Process)

  • 김동규;박상언;조국래;이규현;김광희;이문용
    • 한국소성가공학회:학술대회논문집
    • /
    • 한국소성가공학회 2009년도 추계학술대회 논문집
    • /
    • pp.297-300
    • /
    • 2009
  • The roll forming process is often used to manufacture long, thin-walled products such as a pipe. The final cross-section is a comparatively simple open-channel, a closed tube section or a complex profile with several bends. In recent years, that process is often applied to the bumper beam in the automotive industries. In this study, a optimal Center Floor Cross Member manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle, and also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

  • PDF

고강도강 자동차 부품의 롤 성형 공정의 탄소성 유한요소해석 (Elastic-Plastic Finite Element Analysis of the Roll Forming Process for an Automotive Part of High Strength Steel)

  • 김광희
    • 한국정밀공학회:학술대회논문집
    • /
    • 한국정밀공학회 2005년도 추계학술대회 논문집
    • /
    • pp.480-483
    • /
    • 2005
  • A roll forming process is developed for an automotive part of high strength steel. Forming rolls are designed through the plane strain elastic-plastic finite element analysis to estimate the springback. It is assumed that the process can be approximated as a series of multi-step bending processes. Then the 3D elastic-plastic finite element analysis with the solid element is carried out for the designed roll forming process. The prototype roll forming machine and the forming rolls are made and the experiments are carried out. The results of the analysis and the experiments are compared.

  • PDF