• 한국정밀공학회지
• /
• 제21권9호
• /
• pp.95-102
• /
• 2004

A flexible incremental roll forming process has been developed by adopting the advantages of the incremental forming process and the roll forming process: i.e., inherent flexibility of the incremental forming process and continuous bending deformation of the roll forming process. It has an adjustable roll set as a forming tool composed of one upper center roll and two pairs of lower support rolls, which plays a key role during forming process. Through the experiments based on the various combinations of process parameters, it is shown that the incremental roll forming process is so effective as to manufacture various doubly curved sheet metals including concave-convex combination shapes in which there exists a line of inflection. The proposed relationship of the experimental parameters and the radius of curvature of the formed sheet boundary is found to be useful in prediction and control of the final shape.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 춘계학술대회 논문집
• /
• pp.978-981
• /
• 2005

In order to manufacture a doubly curved sheet metal effectively, a flexible incremental roll forming process has been developed by adopting the advantages of the incremental forming process and the roll forming process by combining inherent flexibility of the incremental forming process and continuous deformation of the roll forming process. The forming method has been further enhanced to form general quadrilateral blanks (including a square, a rectangle, a symmetrical trapezoid and an asymmetrical trapezoid, etc.) into doubly curved shapes by controlling the forming paths developed by various experiments.

• 산업경영시스템학회지
• /
• 제38권4호
• /
• pp.177-183
• /
• 2015

Incremental sheet metal forming is a manufacturing process to produce thin parts using sheet metals by a series of small incremental deformation. The process rarely needs dedicated dies and molds, thus, preparation time for the process is relatively short as to be compared to conventional metal forming. Spring back in sheet metal working is very common, which causes critical errors in dimensions. Incremental sheet metal forming is not fully investigated yet. Hence, incremental sheet metal forming frequently produces inaccurate parts. This paper proposes a method to minimize dimensional errors to improve shape accuracy of products manufactured by incremental forming. This study conducts experiments using an exclusive incremental forming machine and the material for these experiments are sheets of aluminum AL1015. This research defines a process parameter and selects a few factors for the experiments. The parameters employed in this paper are tool feed rate, tool diameter, step depth, material thickness, forming method, dies applied, and tool path method. In addition, their levels for each factor are determined. The plan of the experiments is designed using orthogonal array $L_8$ ($2^7$) which requires minimum number of experiments. Based on the measurements, dimensional errors are collected both on the tool contacted surfaces and on the non-contacted surfaces. The distances between the formed surfaces and the CAD models are scanned and recorded using a commercial software product. These collected data are statistically analyzed and ANOVAs (analysis of variances) are drawn up. From the ANOVAs, this paper concludes that the process parameters of tool diameter, forming depth, and forming method are the significant factors to reduce the errors on the tool contacted surface. On the other hand, the experimental factors of forming method and dies applied are the significant factors on the non-contacted surface. However, the negative forming method always produces better accuracy than the positive forming method.

• 한국정밀공학회지
• /
• 제33권4호
• /
• pp.287-293
• /
• 2016

A monobloc tubular drive shaft is designed to obtain the improved structural safety and the weight reduction of the drive shaft together. The monobloc tubular drive shaft can be manufactured from an incremental hot rotary forging process. The aim of this study was to experimentally determine conditions of an incremental hot rotary forging process for a monobloc tubular drive shaft. Induction heating experiments were performed to estimate a proper heating time of an initial workpiece in an induction heating process. Several incremental hot rotary forging experiments were carried out using a mechanical press with the designed set-up. The step distance and the step angle were chosen as controllable forming parameters. Based on the results of the experiments, the influence of forming parameters on the quality of the forged part was investigated. Finally, a forming map and a proper forming condition of the incremental hot rotary forging process were estimated.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 춘계학술대회 논문집
• /
• pp.812-815
• /
• 2005

The incremental forming process employs several tens or hundreds of continuous local strokes, so the entire process is difficult to analyze due to much computation time and large computer memory. The objective of this work is to propose a new numerical scheme of the finite element method, automatic expansion of domain (AED), and to reduce computation time and computer memory. In the AED scheme, an effective analysis domain in each local forming step is defined and then the domain is automatically expanded in accordance with the repeated process. In order to verify the validity of the criterion for the AED scheme and the applicability of the AED scheme, two-dimensional incremental plane-strain forging process is first analyzed using the proposed scheme with various criteria and full domain. In addition, three-dimensional incremental radial forging process is analyzed to verify the applicability of the proposed scheme to a practical incremental forging process.

• 소성∙가공
• /
• 제17권1호
• /
• pp.27-34
• /
• 2008

In order to manufacture a doubly curved sheet metal, the incremental roll forming process which adopts advantages such as the flexibility of the incremental forming process and continuous bending deformation of the roll forming process has been experimentally investigated. An experimental equipment was developed which was named as unit roll set (URS) consisting of two pairs of support rolls and an upper center roll. The upper roll equipped with the servo control unit is motor-driven and can be positioned in the vertical direction according to the user's commands. Four support rolls are idle, and they freely rotate only along the axis so as to transfer the plate more stably in the tangential direction of the rotation of the driving roll. In the process, the plate is deformed incrementally as deformation proceeds simultaneously in longitudinal and transverse directions. Through the experiments using URS, information regarding to forming schedules is found out to fabricate curved hull plates. This study demonstrates the further application of the incremental roll forming process in shipbuilding industries.

• Architectural research
• /
• 제18권4호
• /
• pp.121-128
• /
• 2016

Low-income housing policies in South Korea have been pursued mostly by providing public rental housing for less privileged social groups. In contrast to this notion of housing, this article argues for housing ownership by low-income families. Two examples of this ownership policy are found in Chile. Incremental housing involves an open-ended housing platform, which requires home-dwellers to complete the construction process themselves. This article aims to examine structural, spatial and formal characteristics of the incremental housing projects. Taking the perspective of the home-dweller during the incremental construction process, we evaluate the houses before and after customization. Thus, we use data from field-work conducted for seven months in the Santiago Metropolitan Area of Chile. Using qualitative methods such as observation, semi-structured interviews, and surveys we focus on the Elemental Lo Espejo incremental housing project and then compare it with the Las Higuera housing project. The latter is representative of the incremental houses delivered by the Chilean government. In comparing these two projects, we aim to articulate the lessons of incremental housing with the intention of suggesting possible future developments for a wider-reaching incremental housing program.

• 소성∙가공
• /
• 제3권1호
• /
• pp.110-119
• /
• 1994

In this paper, a new forming process of large-size forgings of converged nozzle-shape is developed by the experimental study using the incremental forging method and combined forming method. The development of the forming process is focused on the manufacturing of large-size forgings by the press with medium load capacity. Various related processes are proposed and modelling experiments using plasticine are carried out. Thus, the incremental forging method for expanding is recommanded from the study of formability and forming load, etc. The selected process is then subjected to modelling experiments of lead and the design parameters such as preform for final process, die-width of the upper die and reduction amount of each stroke are determined. In order to verify the effectiveness of the selected process, 1/7 scale prototype experiment of the real material is carried out. Forgings of converged nozzle shape can be produced by the developed process within the limit loads and with the simple tools.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2005년도 추계학술대회 논문집
• /
• pp.322-325
• /
• 2005

In order to make a doubly-cowed sheet metal effectively, the sheet metal forming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation in thickness. The developed process is an unconstrained forming process without holder. The experimental equipment has been set up with the roll set which consists of two pairs of support rolls and one center roll. In order to analyze process parameters in the incremental roll forming process for the application to doubly curved ship hull plate, the orthogonal array is adopted. From the FEM results, among the process parameters, the distance between supporting rolls in pairs along the direction of one principal radius of curvature as well as the forming depth is shown to influence the generation of curvature in the same direction significantly. That is, the other distance between supporting rolls in pairs which are not located in the same direction of one principal radius of curvature, does not have an significant effect on the generation of the curvature in that direction. Also, the forming load and torque from the FEM simulation are acceptable to the system development of the incremental roll forming process for the forming of ship hull plate.

• 정보처리학회논문지A
• /
• 제13A권4호
• /
• pp.289-294
• /
• 2006

검사점 기법은 시스템이 장애를 내재한 경우에 효과적으로 프로세스가 장애 지점으로부터 다시 시작 할 수 있게 하는 결함 허용 방법이다. 특히, 페이지 단위 점진적 검사점 기법은 검사점 사이에서 변경된 페이지 데이터만을 저장함으로써 검사정 기록 오버헤드를 감소시킨다. 이 기법은 매 검사점 사이에서 변화하는 데이터의 크기가 가변적이므로 검사점 수행 시간도 매번 변하는 성질을 갖고 있다. 기존의 연구로 고정적인 검사점 수행 시간을 갖는 경우에 대한 효율적인 검사점 작성 시점 결정 방법이 제시된 바 있다. 그러나 매 검사점 마다 가변적인 시간을 필요로 하는 페이지 단위 점진적 검사점 기법에 대한 효율적인 작성 시점 결정 방법은 아직 연구되지 않은 분야이다. 본 논문에서는 효율적이고 적응성 있는 검사점 작성 시점 결정 방법을 제안하고, 이 방법에 기반을 둔 적응성 있는 페이지 단위 점진적 검사점 기법을 보인다. 여러 가지 용용 프로그램의 실험 결과를 통하여, 제안한 방법을 사용하는 것이 기존의 고정적인 인터벌을 갖는 페이지 단위 점진적 검사점을 사용하는 경우보다 프로세스의 평균 수행 시간을 현저히 줄임을 알 수 있다.