• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.1
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• pp.45-50
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• 2011

Hot-Press-Forming (HPF), an advanced sheet metal forming method using stamping at a high temperature of about $900^{\circ}C$ and quenching in an internally cooled die set, is one of the most successful forming process in producing crash-resistant parts such as pillars and bumpers with complex shape, ultrahigh strength, and minimum springback. To optimize conditions of a forming quality in HPF process and secure a safe product without any failures, such as fractures and wrinkling, the simulations based on the coupled thermo-mechanical analysis for a hot-press-formed lower control arm are applied with Taguchi's orthogonal array experiment. Three factor variables - the friction coefficient, blank shape, and hole location for burring - are selected to be optimized. The most effective condition of a forming quality for a hot-press-formed lower control arm is suggested. The simulation results are confirmed with experimental ones.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.97-100
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• 2003

Globally, the various machine components, as in electronics and communications, are demanded to being high-performance and micro-scale with abrupt development of the fields of computers, mobile communications. As this current tendency, production of the parts that must have high accuracy, so called milli-structure, are accomplished by the method of top-down, differently as in the techniques of MEMS, NANO. But, in the case of milli-structure, production procedure is highly costs, difficult and demands more accurate dimension than the conservative forming, processing technique. In this paper, forming analysis of the micro-former as the milli-structure are performed and then calculate the punch force etc. This information calculated is applied to decide the forming capacity of micro-former and design the process of forming stage, dimension of dies in another forming bodies. And, for the better precise forming analysis, elasto-plastic analysis is to be performed, then the consideration about effect of elastic recovery when punch and die are unloaded, have to be discussed in change of dimensions.

• Transactions of Materials Processing
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• v.17 no.1
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• pp.35-45
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• 2008

Electromagnetic Forming (EMF) technology such as magnetic pulse forming, which is one of the high velocity forming methods, has been used for the joining and forming process in various industry fields. This method could be derived a series of deformation of sheet metal by using a strong magnetic field. In this study, numerical approach by finite element simulation of the electromagnetic forming process was presented. A transient electromagnetic finite element code was used to obtain the numerical model of the time-varying currents that are discharged through the coil in order to obtain the transient magnetic forces. Also, the body forces generated in electromagnetic field were used as the loading condition to analyze deformation of thin sheet metal workpiece using explicit dynamic finite element code. In this study, after finite element analysis for thin sheet metal forming process with free surface configuration was performed, analytical approach for a dimpled shape by using EMF was carried out. Furthermore, the simulated results of the dimpled shape by EMF were compared with that by a conventional solid tool in view of the deformed shape. From the results of finite element analysis, it is confirmed that the EMF process could be applied to thin sheet metal forming.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.9
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• pp.1-6
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• 2018

Hydro-forming technology has spread dramatically throughout automotive industry over the last 20 years. This technology has many advantages for automotive applications in terms of better structural integrity of the parts, lower cost from fewer parts, material savings, weight reduction, lower springback, improved strength, durability, and design flexibility. In this study, various simulation technologies were developed to investigate the formability of hydro-forming components. Through this technology, to establish the effective forming process for appropriate components design, the bending process, pre-forming process, die closing process, etc. were considered for good forming. This paper proposes the forming amount, section length (corresponding to the hydro-forming press capacity), and minimum curvature (curvature effect evaluation according to the hydro-forming pressure) among the considerations in the design of the hydro-forming part. In addition, a design method is proposed for hydro-forming molding by carrying out cross section analysis of a real sub-frame part for automobiles. The effects of pre-bending, axial feed, hydraulic pressure, press load, and friction among the hydro-forming process parameters were analyzed. Therefore, whether these processes are necessary factors for hydro-forming were examined.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.589-590
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• 2006

Based on the comparison of structures and properties of the HS6-5-2 high speed steels made with the powder injection moulding method, pressureless forming, compacting and sintering, and commercial steels made with the ASEA-STORA method, fine carbides spread evenly in the steel matrix were found in the structure of all tested high-speed steels in the sintered state. The steels made with the pressureless forming method are characteristic of the lowest sintering temperature and the highest density, resulting from the high carbon concentration coming from the binding agent degradation.

• Transactions of Materials Processing
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• v.21 no.7
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• pp.441-446
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• 2012

A sequential coupled field analysis of electromagnetic free bulging was performed by using FEM. A 2D axi-symmetric electromagnetic model based on the magnetic vector potential is proposed for the calculation of magnetic field and Lorentz's forces. The Newmark integration method is used to calculate the transient dynamic plastic deformation of sheet during free bulging. In the finite element model, the effect of sheet deformation on the electromagnetic field analysis is taken into consideration. In order to confirm the sequential electromagnetic-mechanical coupling analysis, an experiment with an electromagnetic forming apparatus was conducted. The results showed that the final bulge height of the sheet predicted from the proposed method is in good agreement with experimentally measured height.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.89-92
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• 2001

A rigid-viscoplastic finite element code for superplastic forming processes has been developed The material is assumed to be isotropic and a modified Coulomb friction law is adopted to explain contact between tool and sheet. This code uses the triangular element based on the membrane approximation and a hierarchical contact searching method is implemented The optimum pressure-time relationships for target strain rate are calculated by several pressure control algorithms. By the analysis, optimum pressure-time curves and deformation behavior are predicted.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.1 s.178
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• pp.152-158
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• 2006

The AutoForm previously used the membrane element and it accomplished sheet metal forming analysis. The membrane analysis has been widely applied to various sheet metal forming processes because of its time effectiveness. However, it is well-known that the membrane analysis can not provide correct information for the processes which have considerable bending effects. In this research experimental results were compared with the analysis results obtained by using the shell element which is applied newly in the AutoForm commercial software. The shell element is a compromise element between continuum element and membrane element. The Finite element method by using shell element is the most efficient numerical method. From this research, it is known that FEA by using shell element can predict accurately the problems happened in actual experimental auto-body panel.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.278-282
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• 2003

There is a strong industrial demands for the development of light-vehicle to improve fuel efficiency. It is more effective to reduce weight of the parts directly driven by an automobile engine. So the saving in weight of wheels which is operated by an automobile engine improve fuel efficiency more than other parts. There are many step of sheet metal forming in fabricating automotive wheel, so that it is difficult to design process and tools of multi-stage stamping. Traditionally, design process and tools have depended on the experience of skilled workers and it has done by trial and error methods. However, it needs too much costs and time. Taguchi methods has an advantage of the number of required experiments and reliability compared with trial and error method. In this study, Taguchi methods and response surface methods are applied to design process and tools of automotive wheel. As a result, the principal variables are selected and process conditions are optimized.

• Transactions of Materials Processing
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• v.16 no.2 s.92
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• pp.138-143
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• 2007

Superplastic forming/diffusion bonding (SPF/DB) processes were analyzed using a 3-D rigid visco-plastic finite element method. A constant-triangular element based on membrane approximation and an incremental theory of plasticity are employed for the formulation. The coulomb friction law is used for interface friction between tool and material. Pressure-time relationship for a given optimal strain rate is calculated by stress and pressure values at the previous iteration step. In order to improve the contact searching, hierarchical search algorithm has been applied and implemented into the code. Various geometries including sandwich panel and 3 sheet shape for 3-D SPF/DB model are analyzed using the developed program. The validity fer the analysis is verified by comparison between analysis and results in the literature.