• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.28-31
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• 1998

Wrinkling is one of the major defects in sheet metal products and may be also attributable to the wear of the tool. The initiation and growth of the wrinkles are influenced by many factors such as stress state, mechanical properites of the sheet material, geometry of the body, and contact condition. It is difficult to analyze the wrinkling initiation and growth considering the factors because the effects of the factors are very complex and the wrinkling behavior may show wide variation for small deviation of the factors. In this study, the bifurcation theory is introduced for the finite element analysis of wrinkling initiation and growth, All the above mentioned factors are conveniently considered by finite element method. The finite element formulation is based on the incremental deformation theory and elastic-plastic material modeling. The finite element analysis is carried out using the continuum-based resultant shell elements considering the planar anisotropy of the sheet metal. The proposed method is verified by employing to column buckling problem. And then, the initiation and growth of wrinkling in deep drawing of cylindrical cup are analyzed.

• 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.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.8
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• pp.2113-2122
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• 1994

The 3-D FEM analysis for simulating the stamping operation of planar anisotropic sheet metals with arbitrarily-shaped tools is introduced. An implicit, incremental, updated Lagrangian formulation with a rigid-viscoplastic constitutive equation is employed. Contact and friction are considered through the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshes without depending on the explicit spatial derivatives of tool surfaces. The consistent full set of governing relations, comprising equilibrium equation and mesh-normal geometric constraints, is appropriately linearized. The linear triangular elements are used for depicting the formed sheet, based on membrane approximation. Barlat's non-quadratic anisotropic yield criterion(strain-rate potential) is employed, whose in-plane anisotropic properties are taken into account with anisotropic coefficients and non-quadratic function parameter. The planar anisotropic finite element formulation is tested with the numerical simulations of the stamping of an automotive hood inner panel and the drawing of a hemispherical punch. The in-plane anisotropic effects on the formability of both mild steel and aluminum alloy sheet metals are examined.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.14-17
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• 1999

The wrinkling behavior of a thin sheet with perfect geometry is a kind of compressive instability. The compressive instability is influenced by many factors such as stress state mechanical properties of the sheet material geometry of the body contact conditions and plastic anisotropy. The analysis of compressive instability in plastically deforming body is difficult considering all the factors because the effects of the factors are very complex and the instability behavior may show wide variation for small deviation of the factors. In this study the bifurcation theory is introduced for the finite element analysis of puckering initiation and growth of a thin sheet with perfect geometry. All the above mentioned analysis and the post-bifurcation behavior is analyzed by introducing the branching scheme proposed by Riks. The finite element formulation is based on the incremental deformation theory and elastic-plastic material modeling. in order to investigate the effect of plastic anisotropy on the compressive instability a square plate that is subjected to compression in one direction and tension in the other direction is analyzed by the above-mentionedfinite element analysis. The critical stress ratios above which the buckling does not take place are found for various plastic anisotropic modeling method and discussed. Finally the effect of plastic anisotropy on the puckering behavior in the spherical cup deep drawing process is investigated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1992.03a
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• pp.201-212
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• 1992

The plane strain analysis for simulating the stretch/draw forming operation of arbitrarily-shaped tool profiles and arbitrarily draw-in conditions is introduced. An implicit, incremental, updated Lagrangian formulation is employed, introducing a rigid-viscoplastic constitutive equation. Contact and friction are considered through the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshe without depending on the explicit spatial derivatives of tool surfaces. The FEM formulation is tested in the sections automotive inner panel and two-side draw-in. Not only the excellent agreement between measured and computed strains in the stretched section is obtained, but also the numerical stability of current formulation is verified in the two-side draw-in section.

• Elastomers and Composites
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• v.44 no.4
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• pp.384-390
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• 2009

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. The solar cell plate may have millions 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-to-roll forming process. Also formability is analysed for various number of mesh, protrusion shapes and forming temperature.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.590-595
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• 2007

This paper introduces a new approach to take account of bending history in finite element inverse analysis during sheet metal forming process. A modified membrane element was adopted for finite element inverse analysis so that bending-unbending energy was additionally imposed in the total plastic energy, predicting bending-unbending regions using the geometry of the final shape and tools. An algorithm was applied to a cylindrical cup deep drawing process. The blank shape and the distribution of the thickness strain were compared with those obtained from the incremental finite element analysis in order to evaluate the effect of the bending history. The algorithm reduced the difference between the results of the inverse analysis from those of the incremental analysis due to bending history. The analysis was also carried out with the variation of the thickness of the initial blank to investigate the effect of bending deformation. The results showed that the difference was remarkably reduced as the thickness of the initial blank increased. This indicates that the finite element inverse analysis cooperated with the suggested scheme is useful to obtain more accurate results, especially when bending effects are significant.