• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.201-206
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• 2007

In this paper, we apply a three-dimensional rigid-plastic finite element method to simulate an unsteady-state roll forming process. A typical roll forming process is investigated from the standpoint of computer simulation and its realistic analysis model is proposed. The material is considered as bulk material and discretized into hexahedral finite elements. The presented approach is applied to simulating the roll forming process of straight stringer used for aircraft structure.

• Journal of Power System Engineering
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• v.16 no.6
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• pp.52-58
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• 2012

Roll forming process is one of the most widely used processes in the world for forming metals such as a furniture drawer guide or an up and down slide guide. It can manufacture goods of the uniform cross section on a large scale throughout the continuous processing. In the domestic design and manufacture, roll forming process for production is taking most of the method of 2-point under rail slide. However, this method is vulnerable to the structural strength and stiffness is not suitable for high load conditions. Therefore, through systematic study of high load, low noise 3-point ball type of under rail slide its own design and manufacturing technology is the need to build. In this paper, to make center member of 3-point ball-type under rail slide for the refrigerator doors, the roll forming modeling and simulation are performed. Tensile test is performed about SCP-1 1/2H for determine the mechanical properties of materials. Modeling and simulation of roll forming is used MSC.MARC software of a dedicated analysis program used by rigid plastic finite element method. Interference between the roll and the final shape are predicted from the results of the simulation.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.8
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• pp.840-844
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• 2012

Roll forming process is a sheet metal forming process where the forming occurs with rolls in several steps, often from an undeformed sheet to a product ready to use. And each pair of forming rolls installed in a forming machine operates a particular role in making up the required final cross-section. This process used to many industry manufactures and recently apply to automotive industry. This study, FEM simulation applied bumper reinforcement using SHAPE-RF software and analyzed about total effective strain, longitudinal strain, thickness according to the roll-pass.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.4
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• pp.27-32
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• 2010

This paper presents an investigation into the pinhead forming process with the objective of finding the optimal forming conditions. In order to this, the orbital forming analysis of a heading MIG was carried out using the explicit finite element method. Relationships between temperature by forming of load and stresses, rake angle by forming final shape and stress distribution were investigated through analysises in order to find an efficient solution. As a result, the higher temperature and orbital rake angle were the better forming conditions.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.4
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• pp.175-181
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• 2018

Stamping process and rubber pad forming process were performed to manufacture the bipolar plate for fuel cells. For that, a vacuum die casting process and a semi-solid forming process wherein liquid-state materials were used were adopted. After preparing the blank with the stainless steel thin plate having a thickness of 0.1 mm, the bipolar plate channel was formed with the stamping process and rubber pad forming process. The depth of the bipolar plate channel prepared by the stamping method was 0.45 mm and the depth of the bipolar plate channel prepared by the rubber pad forming process was 0.41 mm. Meanwhile, with the vacuum die casting and semi solid forming, the bipolar plate having a channel depth of 0.3 mm, same as the size of the die, could be formed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.66-69
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• 2004

A new concept of multi-point dieless elasto-forming method has been developed to make various shape of curved surface without conventional dies. The developed dieless elasto-forming system consists of discrete punches controlled by servo motors and various kinds of elastomers(rubber and foam). To predict optimal position of punch elements, DTF(deformation transfer function) was introduced, and FEM analysis was carried out. The optimal arrangement of elastomer was selected considering characteristics of each elastomer, and a desired concave shape was formed. The experimental results were consistent with the numerical ones.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.265-268
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• 2006

The superplastic forming/diffusion bonding is widely accepted as an advanced technique for forming complex industrial components. But the superplastic forming process requires much forming time and generates excessive thinning thickness distribution of formed part. Superplastic in materials is only achieved in a narrow range of strain-rate with optimum value unique to each material. In this study, finite element analysis for surperplastic forming/diffusion bonding (SPF/DB) processes of three-sheet and four-sheet sandwich parts. From this study, forming analysis have offered a lot of information for developing the forming process.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.114-120
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• 2008

This study is to compare and analyze the material flow, deformation characteristics, and forming load of flange by means of similitude experimental method of model material using plasticine. In order to find optimal forming conditions, prototype experiments were designed to investigate forming characteristics of general-purpose flange under various working conditions. As a result of prototype experiments, billet thickness and gap-height ratio was found to be the most influential experimental parameter in flange forming. Forming loads from prototype experiments were compared to the results of finite element analysis after conducting estimation of forming loads of real material. Results of prototype experiments based on model material techniques are expected to be used as a basic data of die design f3r the development of products and process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.97-100
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• 2005

The purpose of this study is to apply the partial-size die forming process to actual segment head farming process of semi-ellipsoidal heads and to verify the availability of the suggested forming method. The initial curvature for the preliminary forming process was determined through anticlastic behavior of plate bending and the partial-size die for final forming was designed based on the results of springback analysis using F.EA. From the results of actual forming, it was concluded that die design was appropriate and proposed forming process would be successfully applied to actual forming jobs.

• Transactions of Materials Processing
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• v.9 no.5
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• pp.453-462
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• 2000

Tailor-welded blanks are used for forming of automobile structural skin components. The main objective of this study is to achieve weight and cost reduction in manufacturing of components. For successful application of tailor-welded blanks, design of initial welded blanks and prediction of the welding line movement are critical. The utilization of the backward tracing scheme of the finite element method shows to be desirable in design of initial welded blanks for net-shape production and in prediction of the welding line movement. First the design of the initial blank in forming of welded thick sheet with isotropy is tried, and it appears successful in obtaining a net-shape stamping product. Based on the first trial approach, the backward tracing scheme is applied to anisotropic tailored blanks. The welding line movement is also discussed.