• 산업경영시스템학회지
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• 제39권4호
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• pp.90-96
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• 2016

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Compared to conventional sheet forming processes, ISF is of a clear advantage in manufacturing small batch or customized parts. ISF needs die-less machine alone, while conventional sheet forming requires highly expensive facilities like dies, molds, and presses. This equipment takes long time to get preparation for manufacturing. However, ISF does not need the full facilities nor much cost and time. Because of the facts, ISF is continuously being used for small batch or prototyping manufacturing in current industries. However, spring-back induced in the process of incremental forming becomes a critical drawback on precision manufacturing. Since sheet metal, being a raw material for ISF, has property to resilience, spring-back would come in the case. It is the research objective to investigate how geometrical shaping parameters make effect on shape dimensional errors. In order to analyze the spring-back occurred in the process, this study experimented on Al 1015 material in the ISF. The statistical tool employed experimental design with factors. The table of orthogonal arrays of $L_8(2^7)$ are used to design the experiments and ANOVA method are employed to statistically analyze the collected data. The results of the analysis from this study shows that the type of shape and the slope of bottom are the significant, whereas the shape size, the shape height, and the side angle are not significant factors on dimensional errors. More error incurred on the pyramid than on the circular type in the experiments. The sloped bottom showed higher errors than the flat one.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 춘계학술대회 논문집
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• pp.215-219
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• 2009

For the effective manufacture of doubly curved metal plates, a line array roll set (LARS) process is proposed. The suggested process utilizes a pair of upper and lower symmetric roll assemblies. In the process, the initial plate is progressed into the final shape in a stepwise or pathwise manner according to the basic principle of the incremental forming process. In this work, the intermediate shape which is closest to a final shape is proposed to fabricate the desired shape effectively in design of forming schedule. The intermediate shape has homogeneous curvature in a longitudinal and transverse direction so that it can be fabricated easily without complicated controls of rolls in the roll set. The method of approximation using genetic algorithm is proposed and applied to some actual ship hulls to evaluate the efficiency of the algorithm.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2011년도 춘계학술대회 논문집
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• pp.883-884
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• 2011

• 한국산학기술학회논문지
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• 제21권1호
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• pp.560-567
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• 2020

점진판재성형은 금형을 제작하지 않고 판재를 가공하는 방법으로서 빠른 시제품 제작과 소량 생산에 적합한 성형법이다. 이러한 점진판재성형의 공정 변수로 공구 직경, 매 스탭당 Z-방향 깊이, 공구 이송 속도, 공구 회전 속도 등은 성형품의 품질에 크게 영향을 미친다. 본 연구에서는 두께가 1.0mm인 Al3004판재를 사용하여 원뿔절두체(VWACF: Varying Wall Angle Conical Frustum) 모델의 점진성형을 실시하였으며, 각각의 변수들의 조합에서 성형성을 판단하였다. BP신경망 (BPNN: Back Propagation Neural Network)를 기반으로 Minitab 소프트웨어를 사용하여 성형 각도를 예측하는 2 차 수학적 모델을 구축하였다. 또한 이 모델을 유전 알고리즘의 목적함수로 사용하였으며 최대 성형 각도로 얻기 위한 최적의 변수 조합을 찾아내었다. 공구 직경은 6mm, 회전 속도는 180rpm, Z-방향 피치는 0.401mm, 이송 속도는 772.4mm/min일 경우 가장 큰 성형 각도인 87.071°를 갖는 컵을 성형할 수 있었다.

• 대한기계학회논문집A
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• 제36권9호
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• pp.1073-1080
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• 2012

점진성형은 공구 운동으로 소재의 국부 소성변형 영역을 전체 소재에 확장시켜 목표 형상으로 변형시키는 냉간 성형공정이다. 본 논문에서는 점진성형의 유한요소해석 시 묘사기법에 관한 연구를 수행하였다. 고찰할 묘사기법으로 라그랑지언 묘사법과 ALE 묘사법을 선택하였다. 미끄럼 경계기법도 공구와 접촉표면에서 요소의 찌그러짐을 극복하기 위한 방법중의 한가지 경우로 고찰하였다. 묘사기법과 경계기법의 다양한 조합 중에 ALE 묘사법과 연계한 미끄럼 경계기법의 경우가 요소의 찌그러짐을 가장 완화 시켰다. 이 방법이 최종 단계 변형까지 점진성형 해석을 지속할 수 있도록 해주는 유일한 조합인 것으로 나타났다. 이에 반해, 라그랑지언 묘사법 및 순수 ALE 묘사법은 점진성형 해석 중에 요소의 찌그러짐이 극심하여 최종 변형 형상에 도달하기 오래 전에 해석이 중단되는 상태를 보였다.

• 소성∙가공
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• 제20권4호
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• pp.279-283
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• 2011

Recently incremental sheet metal forming (ISF) has used widely in making prototypes and small-volume products in automotive industry etc. We apply the ISF to make a 1/4 sized automobile body-in-white. First, ISF tests for rectangular shaped cup have been performed to clarify the formability denoting the relationship between the component wall angle and maximum cup height of safe forming. Next, a CAD model for the automobile was designed and segmented into several components in order to accommodate the working space of the CNC machine we adopted and the formability of the sheet metal. Then, a CAM software was employed to generate the tool path for manufacturing wooden dies and all the small parts. Finally, the different parts were joined into a single component by laser welding after the ISF process. By using the ISF we successfully produced the 1/4 sized automobile body-in-white.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 추계학술대회 논문집
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• pp.289-292
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• 2009

The line array roll set process, as one of many kinds of incremental forming processes, is a continuous process in which a flat metal plate is formed into a singly or doubly curved plate through successive passes of forming rolls. It was found that the curvature level of the formed plates in the previous study was well over the curvature required in shipyards. This fact shows that the LARS method has considerable potential for shipbuilding applications. In a shipbuilding yard, hull forming is an important fabrication process in which flat plates are deformed into singly or doubly curved plates. The major purpose of the present study is to estimate experimentally the general applicability of the line array roll set process for the manufacture of ship hull plates. In this study, the target shapes are selected through investigation of the shape classification of ship hull plates that comprise a certain vessel. Forming processes for twisted shapes are analyzed with the finite element method (FEM). Finally, the results of experimental work for two types of target shapes are presented.

• 소성∙가공
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• 제10권1호
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• pp.59-66
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• 2001

Recently, the technology of incremental forming for sheet metal components has drawn attention for small-batch productions. In the present investigation, a forming tool containing a freely-rotating ball was developed and applied to forming of various shapes with full annealed Al 1050 sheet. Deformation characteristics occurring during forming with this tool was examined through FEM analysis and grid measurement. It was found that deformation modes developed along a straight path and around a corner are close to those of plane-strain and equi-biaxial stretching, respectively, and that cracks occur mostly at corners for the same depth of tool. FEM analysis was successfully applied to this special type of forming process and provided comparable results to the measurements from experiment.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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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.

• 소성∙가공
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• 제19권2호
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• pp.120-126
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• 2010

The line array roll set(LARS) process, as one of many kinds of incremental forming processes, is a continuous process in which a flat metal plate is formed into a singly or doubly curved plate through successive passes of forming rolls. It was found that the curvature level of the formed plates in the previous study was well over the curvature required in shipyards. This fact shows that the LARS method has good potential for shipbuilding applications. The major purpose of the present study is to estimate experimentally the general applicability of the line array roll set process for the manufacture of ship hull plates. In this study, the target shapes are selected through investigation of the shape classification of ship hull plates that comprise a certain vessel. Forming processes for twisted shapes are analyzed with the finite element method(FEM) and the results of experimental work are presented. On the basis of the experimental and numerical results, the LARS process is applied to the production of real outer hull plates of a small patrol ship.