• International Journal of Automotive Technology
• /
• v.6 no.5
• /
• pp.519-527
• /
• 2005

Recently, weight reduction of vehicles has been of great interest and consequently the use of low-density materials in the automotive industry is increasing every year. However, the substitution of one material for another is not simple because it accompanies several problems, for example, weakness in the strength and stiffness and difficulty in the joining. To overcome these problems, the structure of the automobile redesigned totoally. Aluminum spaceframe is rapidly being adopted as a body structure for accommodating lightness, stiffness and strength requirement. In aluminum spaceframe manufacturing, it is often required to join aluminum tube. However, there are few suitable methods for joining aluminum tube, so that much interest has been focused on testing suitable joining methods. Joining by electromagnetic forming (EMF) can be useful method in joining aluminum tube, which offers some advantages compared with the conventional joining methods. In this paper, joining by EMF was investigated as a pre-study for applying an automotive spaceframe. Finite element simulations and strength tests were performed to analyze the influence of geometric parameters on joint strength. Based on these results, configurations of axial joint and torque joint were suggested and guidelines for designing EMF joint were established.

• Journal of the Korean Society for Precision Engineering
• /
• v.13 no.12
• /
• pp.86-98
• /
• 1996

An combined implicit/explicit scheme for the analysis of sheet forming problems has been proposed in this work. In finite element simulation of sheet metal forming processes, the robustness and stability of computation are important requirements since the computation time and convergency become major points of consideration besides the solution accuracy due to the complexity of geometry and boundary conditions. The implicit scheme dmploys a more reliable and rigorous scheme in considering the equilibrium at each step of deformation, while in the explict scheme the problem of convergency is elimented at thecost of solution accuracy. The explicit approach and the implicit approach have merits and demerits, respectively. In order to combine the merits of these two methods a step-wise combined implici/explicit scheme has been developed. In the present work, the rigid-plastic finite element method using bending energy augmented membraneelements(BEAM)(1) is employed for computation. Computations are carried out for some typical sheet forming examples by implicit, combined implicit/explicit schemes including deep drawing of an oil pan, front fender and fuel tank. From the comparison between the methods the advantages and disadvantages of the methods are discussed.

• Composites Research
• /
• v.23 no.6
• /
• pp.55-60
• /
• 2010

In this paper, tensile and bending tests of glass/polypropylene composite (Twintex) specimens fabricated by various forming conditions were carried out and the results were compared according to the forming conditions to find the appropriate condition for the forming composite bone plates. From the tests it was found that the most appropriate forming conditions were $230^{\circ}C$, 3MPa. Composite bone plates were formed using this condition by two different fabricating methods for screw holes: one was a net shape molding and the other was drilling. The forming and bending tests revealed that the drilling process provided much better bending stiffness of bone plates. This paper provided the most appropriate condition for forming composite bone plates and this result was also expected to offer informative data on forming of other Twintex structures.

• Transactions of Materials Processing
• /
• v.10 no.4
• /
• pp.319-328
• /
• 2001

Quantitative evaluation of the tribological conditions at the tool-workpiece interface in metal forming is usually accomplished by the ring compression test. This paper describes an experimental investigation into friction factor under warm forming conditions according to the lubricants and the lubricating methods using the ring compression test. Four different lubricants, two water based graphite and two oil based graphite lubricants, and three different lubricating methods were applied in the experiments. Calibration curves with the friction shear factor were obtained using FEM analysis and verified by the experimental results. The influence of lubricant and lubricating methods on friction are discussed. In the ring compression test, the lower friction factor got to spray the oil based lubricant on die and billet in warm forging temperature.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2007.05a
• /
• pp.135-138
• /
• 2007

A semi-solid forming processing has been developed for manufacturing near net-shape components. The semi-solid forming has two methods. One is thixo-forming with reheating prepared billet, the other is rheo- forming with cooled melt until semi-solid state. In indirect forging processing, this experiment used aluminum rheology materials by electromagnetic stirring system. Rheology material is made by A16061. An experiment has variation factors which are pressure, solid-fraction, stirring current and stirring time. Forged samples are found microstructures and mechanical properties. Forged samples are accomplished heat treatment T6 for high mechanical properties.

• Transactions of Materials Processing
• /
• v.14 no.5 s.77
• /
• pp.439-443
• /
• 2005

Deep drawing and cold forging processes are combined to achieve near net shape forming of automotive part which has not only drum shape but also thickness variation. It is important to find out proper intermediate shape where two totally different forming methods should be joined seamlessly. In the course of development of the combined process, finite element analysis can be utilized effectively to decide optimal position for transferring from the sheet metal work to the bulk forming. Because machining process is eliminated, significant improvement in integrity, reliability, and durability of the part is expected. The developed process combination could be applied in real manufacturing process successfully.

• Proceedings of the KSME Conference
• /
• 2001.06c
• /
• pp.604-609
• /
• 2001

In the sheet metal forming process, the drawbead is used to control the flow of material during the forming process. The drawbead provides proper restraining force to the material and prevents defects such as wrinkling or breakage. For these reasons, many studies for designing the effective drawbead have been conducted. For the analysis, the numerical method called the static-explicit finite element method was used. The finite element analysis code for this method has been developed and applied to the drawbead process problems. In result, convergence problem and computation time due to large non-linearity in the existing numerical analysis methods were no longer a critical problem. Futhermore, this approach could treat the contact friction problem easily by applying very small time intervals. It is expected that various results from the numerical analysis will give very useful information for the design of tools in sheet metal forming process.

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

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.4
• /
• pp.38-47
• /
• 2000

Recently, finite element method has been used as an effective tool in the design process of sheet metal forming. In the present study, an implicit method and an explicit method have been developed for 2D analysis and 3D analysis, respectively, and applied to several processes including plane strain draw bending and TWB sqaure cup drawing. Also, commercial codes are used for geometrically complex problems, such as tube hydroforming, "L" cup deep drawing and side frame forming. In this paper, basic formulations used in the methods are introduced and results obtained from the applications are discussed.discussed.

• Transactions of Materials Processing
• /
• v.20 no.2
• /
• pp.124-131
• /
• 2011

A flexible stretch forming process is useful for small quantity batch production because various shape changes of the flexible die can be achieved conveniently. In this study, the design variables, namely, the punch size, curvature radius and elastic pad thickness, were quantitatively evaluated to understand their influence on sheet formability using statistical methods such as the correlation and regression analyses. Forming simulations were designed and conducted by a three-way factorial design to obtain numerical values of a shape error. Linear relationships between the design variables and the shape error resulted from the Pearson correlation analysis. Subsequently, a regression analysis was also conducted between the design variables and the shape error. A regression equation was derived and used in the flexible die design stage to estimate the shape error.