• Journal of the Korean Society for Precision Engineering
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• v.23 no.2 s.179
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• pp.191-198
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• 2006

Dieless CNC forming is an innovative technology which can form various materials with complex shape by numerically controlled incremental forming process. In this paper, a method of NC tool path generation based on an STL file for dieless CNC forming is proposed. Tool trajectory adopts the principle of layered manufacturing in rapid prototyping technology, but it is necessary to consider STL offset because of the ball shaped tool with a radius. Vertex offset method which enables to compute offset STL directly is engaged for STL offset. The offseted STL is sliced by cutting planes to generate contouring tool path. Algorithm is implemented on a computer and experimented on a dieless CNC forming machine to show its validity.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.10a
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• pp.280-280
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• 2003

• Journal of the Korean Society for Precision Engineering
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• v.33 no.4
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• pp.247-255
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• 2016

Sheet metal-forming processes such as stamping, deep drawing, bending, shearing, hydroforming, hydromechanical deep drawing, rubber forming, and incremental forming have been widely used in the automotive, aircraft, and ship-building industries. With the expansion of the automotive industry, research on these processes has been remarkably developed in Korea since the 1980s. Here, we review the history of this research as well as recent trends in sheet metal-forming processes. This overview focuses specifically on the results of research in Korea and on the works of Professor D.Y. Yang, in honor of his retirement.

• Transactions of Materials Processing
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• v.20 no.8
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• pp.611-618
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• 2011

Flow forming is an incremental forming process in which rollers are used to form cylindrical parts with repeated turning of both roller and starting material. Both sheet and tube can be used as the starting material. The process is highly useful for producing hollow shaped parts from a tube, with the benefit of the average strain in the final shape being significantly lower than that from a sheet material. In the present study, the flow forming process was studied and optimized for producing a hollow shaped part from seamless steel tube by both experiment and numerical analysis. Upon considering the difficulty of forming seamless steel sheet, the thickness reduction was distributed over several tool paths. In the end, an optimum process condition was attained, and the experiment verified the simulation results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.361-364
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• 2008

Incremental forming path to manufacture a thick concave steel plate using the line array roll set is designed. To find the optimum forming path, the forming processes are simulated by the finite element method. A general-purpose commercial software, MSC.MARC is used. The rolls are modeled as rigid surfaces and the thick plate is modeled as 8-node hexahedral elastic-plastic solid elements to predict accurate springback. It is found that the process can be successfully applied to the fabrication of the dual curvature ship hull plate

• Transactions of Materials Processing
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• v.19 no.3
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• pp.167-172
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• 2010

Roll-to-roll forming process is one of important metal processing technology because the process is simple and economical. These days, with these merits, roll-to-roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate. 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. The forming of micro pattern for small electric device such as LCD panel by incremental roll forming process is analyzed. Firstly, the optimum analysis conditions are found by several analyses. And then, formability is analyzed for various protrusion shapes at various forming temperatures. The formability is evaluated in terms of filling ratio and damage value. The filling ratio is defined from the tool geometry and critical damage is determined from the analysis of uniaxial tensile test. Finally, optimum forming conditions that guarantee the successful forming are found.

• Transactions of Materials Processing
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• v.11 no.1
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• pp.84-89
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• 2002

This study is concerned with the analysis of the forming characteristics of radial-forward extrusion. Angle between radial and forward extrusion, gap height, and friction factor are considered as important design factors to affect forming characteristics in radial-forward extrusion. The rigid-plastic finite element method is adopted to analyze the effects of design factors on forming loads. The incremental rates of loads are nearly constant except the deformation zone from radial to forward extrusion. The smaller angle induces lesser force increment, therefore forming load increases as the angle increases. Maximum load also increases as gap-height decreases and friction factor increases.

• Journal of Advanced Marine Engineering and Technology
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• v.18 no.4
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• pp.69-76
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• 1994

Thermal elasto-plastic analysis of axi-symmetric body by the finite element method is presented in this paper for analyzing the process of upset forming of circular section extruded bar. The example of calculation for upset forming of Nimonic extruded bar is also presented. It is shown that remeshing of quadrilateral finite element is necessary because the very highly distorted element by plastic deformation disturbs the calculation. Calculated values for nodal points in new mesh are obtained from nodal points of old mesh by linear interpolation method. The experimental results are compared with calculated values. The appearance of upsetupset forming obtained by experimental method is very similar to that obtained by calculations. So, it is proved that the thermal elasto-plastic analysis of axi-symmetric body by the finite element method is very useful for finding the optimum upsetting condition.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.4
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• pp.118-125
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• 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.

• 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.