• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.379-382
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• 2007

The MEMS (Micro Electro Mechanical Systems) process is used in a micro/nano pattern manufacturing method. This method is based on the lithography technology. But the MEMS process has some problems such as complicated process, long processing time and high production costs. Many researchers are doing research in substitute manufacturing method to work out a solution to these problems. In this paper, we apply a dieless incremental forming technology to a substitute method of MEMS process. This dieless forming technology is using in the commercial scale sheet forming such as a prototype of automobile sheet parts. 5-axes CNC (Computerized Numeric Control) method are applied in this system to get a micro-scale dieless forming results. These 5-axes system are composed of precision AC servo motor stages (4-axes) and PZT actuator (1-axis). A PZT actuator is used in a precision actuating axis because it can be operated in the nano scale stroke resolution. This micro dieless incremental forming system has the advantage of minimization in manipulating distance and working space. As equipment and tools become smaller in size, minute inertia force and high natural frequency can be obtained. Therefore, high precision forming performance can be obtained. This allows the factory to quickly provide the customer with goods because the manufacturing system and process are reduced. To construct this micro manufacturing system, many technologies are necessary such as high stiffness frame, high precision actuating part, structural analysis, high precision tools and system control. To achieve the optimal forming quality, the micro dieless forming system is designed and made with high stiffness characteristic.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.53-56
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• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.56-59
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• 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.

• Transactions of Materials Processing
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• v.12 no.4
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• pp.401-407
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• 2003

This paper newly proposes a mesh regularization method for the enhancement of the efficiency in sheet metal forming analysis. The regularization method searches for distorted elements with appropriate searching criteria and constructs patches including the elements to be modified. Each patch is then extended to a three-dimensional surface in order to obtain the information of the continuous coordinates. In constructing the surface enclosing each patch, NURBS(Non-Uniform Rational B-Spline) surface is employed to describe a three-dimensional free surface. On the basis of the constructed surface, each node is properly arranged to form unit elements as close as to a square. The state variables calculated from its original mesh geometry are mapped into the new mesh geometry for the next stage or incremental step of a forming analysis. The analysis results with the proposed method are compared to the results from the direct forming analysis without mesh regularization in order to confirm the validity of the method.

• 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.

• Structural Engineering and Mechanics
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• v.49 no.5
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• pp.645-660
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• 2014

This paper presents the design and project of an innovative concept for a Single Point Incremental Forming (SPIF) Machine. Nowadays, equipment currently available for conducting SPIF result mostly from the adaptation of conventional CNC machine tools that results in a limited range of applications in terms of materials and geometries. There is also a limited market supply of equipment dedicated to Incremental Sheet Forming (ISF), that are costly considering low batches, making it unattractive for industry. Other factors impairing a quicker spread of SPIF are large forming times and poor geometrical accuracy of parts. The following sections will depict the development of a new equipment, designed to overcome some of the limitations of machines currently used, allowing the development of a sounding basis for further studies on the particular features of this process. The equipment here described possesses six-degrees-of freedom for the tool, for the sake of improved flexibility in terms of achievable tool-paths and an extra stiffness provided by a parallel kinematics scheme. A brief state of the art about the existing SPIF machines is provided to support the project's guidelines.

• Journal of the korean Society of Automotive Engineers
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• v.12 no.6
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• pp.48-59
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• 1990

A finite element program was developed using line elements for simulating the stretch/draw forming operation of an arbitrarily-shaped plane-strain section. An implicit, incremental, updated Lagrangian formulation is employed, introducing a minimum plastic work path assumption for each time step. Geometric and material nonlinearities are also considered within each time step. The finite element equation is based on the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshes without depending on the explicit spatial derivatives of tool surfaces. The membrane approximation is adopted under the plane stress assumption. The sheet material is assumed to obey a rigid-viscoplastic constitutive law. The developed program was tested in the die-tryout of typical automotive inner panels. In order to determine a single friction coefficient and boundary length, FEM results and measurements of thinning for a stretched section of final die were compared. After finding analysis parameters, the sheet forming operations of original and final die designs were simulated. Excellent agreement between measured and computed thickness strains was obtained and the developed program was able to identify die designs which were rejected during die tryout.

• Transactions of Materials Processing
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• v.17 no.7
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• pp.491-495
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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. A modeling with 8-node hexahedral elastic-plastic solid is performed to predict accurate springback and the analysis process was composed of 18 passes. The proposed forming paths are verified through experiments carried out in the prototype line array roll set. It is found that the process can be successfully applied to the fabrication of the dual curvature ship hull plate.

• 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 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