• 소성∙가공
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• 제25권3호
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• pp.182-188
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• 2016

Flexibly-reconfigurable roll forming (FRRF) is a novel sheet metal forming technology conducive to producing multi-curvature surfaces by controlling the strain distribution along longitudinal direction. In FRRF, a sheet metal is shaped into the desired curvature by using reconfigurable rollers and gaps between the rollers. As FRRF technology and equipment are under development, a simulation model corresponding to the physical FRRF would aid in investigating how the shape of a sheet varies with input parameters. To facilitate the investigation, the current study exploits regression analysis to construct a predictive model for the longitudinal curvature of the sheet. Variables considered as input parameters are sheet compression ratio, radius of curvature in the transverse direction, and initial blank width. Samples were generated by a three-level, three-factor full factorial design, and both convex and saddle curvatures are represented by a quadratic regression model with two-factor interactions. The fitted quadratic equations were verified numerically with R-squared values and root mean square errors.

• 한국정밀공학회지
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• 제16권6호
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• pp.123-132
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• 1999

This paper describes a research work of developing computer-aided design of lead frame, semiconductor, with blanking operation which is very precise for progressive working. Approach to the system is based on the knowledge-based rules. Knowledge for the system is formulated from pasticity theories, experimental results and the empirical knowledge of field experts. This system has been written in AutoLISP on the AutoCAD using a personal computer and in I-DEAS Drafting Programming Language on the I-DEAS Master Series Drafting with Workstation, HP9000/715(64). Transference of data between AutoCAD and I-DEAS Master Series Drafting is accomplished by DXF(drawing exchange format) and IGES(initial graphics exchange specification) methods. This system is composed of five modules, which are input and shape treatment, production feasibility check, strip-layout, data-conversion and die-layout modules. The process planning and Die design system is designed by considering several factors, such as complexities of blank geometry, punch profiles, and the availability of a press equipment and standard parts. This system provides its efficiecy for strip-layout, and die design for lead frame, semiconductor.

• 소성∙가공
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• 제16권3호
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• pp.172-177
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• 2007

The process design for large-scale ring rolling of Ti-6Al-4V alloy was performed by calculation method, processing map approach and FEM simulation. The ring rolling design includes geometry design and optimization of process variables. The calculation method was used to make geometry design such as initial billet and blank sizes, and final rolled ring shape. A commercial FEM code, SHAPE-RR was used to simulate the effect of process variables in ring rolling on the distribution of the internal state variables such as strain, strain rate and temperature. In order to predict the forming defects during ring rolling and the formation of over-heating above $\beta$-transus temperature due to deformation heating, the process-map approach based on Ziegler's instability criterion was used with FEM simulation. Finally, an optimum process design to obtain sound Ti-6Al-4V rings without forming defects was suggested through combined approach of Ziegler's instability map and FEM simulation results.

• 소성∙가공
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• 제15권6호
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• pp.445-452
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• 2006

In most of automobile body panel manufacturing, trimming process is generally performed before flanging. To find feasible trimming line is crucial in obtaining accurate edge profile after flanging. Section-based method develops blank along manually chosen section planes and find trimming line by generating loop of end points. This method suffers from inaccurate results of edge profile. On the other hand, simulation-based method can produce more accurate trimming line by iterative strategy. In this study, new fast simulation-based method to find feasible trimming line is proposed. Finite element inverse method is used to analyze the flanging process because final shape after flanging can be explicitly defined and most of strain paths are simple in flanging. In utilizing finite element inverse method, the main obstacle is the initial guess generation for general mesh. Robust initial guess generation method is developed to handle genera] mesh with very different size and undercut. The new method develops final triangular mesh incrementally onto the drawing tool surface. Also in order to remedy mesh distortion during development, energy minimization technique is utilized. Trimming line is extracted from the outer boundary after finite element inverse method simulation. This method has many advantages since trimming line can be obtained in the early design stage. The developed method is verified by shrink/stretch flange forming and successfully applied to the complex industrial applications such as door outer flanging process.

• 한국산학기술학회논문지
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• 제16권9호
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• pp.5789-5794
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• 2015

최근 스마트 폰, 모바일 PC 제품의 외관에 필요한 가벼운 금속제품으로 제조를 하기 위하여 알루미늄 압출 공정과 CNC 가공기법을 적용한 생산방식이 널리 사용되고 있다. 하지만, 알루미늄 압출법은 외관 디자인의 제약이 있으며, 특히 CNC 가공 프로세스가 상대적으로 높은 생산 비용 및 낮은 생산성으로 생산단가가 많이 높은 단점이 있다. 본 연구에서, 새로운 처리 방법을 순서 재료비를 대폭 감소시키고, 제조 속도를 향상시키기 위해 판재성형과 부피성형의 두가지 공정을 섞어 새로운 판단조 공정을 개발하였다. 새로운 판단조 공법(hybrid plate forging)이란 우선 일반적인 딥드로잉으로 중간 모양을 만든 후 원하는 벽 부위만 증육을 하는 방법을 의미한다. 이러한 판단조 공법을 활용하여 재료의 낭비와 제조 시간을 최소화하는 것이 가능하게 된다. 본 연구에서는 상용 유한 요소 프로그램 AFDEX-2D를 통해 판단조공정을 설계하였고 최적의 사용 가능한 소재의 두께와 초기 폭을 설계하였다. 최종적으로 실제 노트북 케이스 금형을 제작하여 제안한 방법의 타당성을 검증하였다.

• 한국항해항만학회지
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• 제34권5호
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• pp.367-373
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• 2010

수치해석을 수행할 경우 좀 더 정확한 수치모의를 위하여 해석영역의 특성에 따라 적절하게 요소를 배치하는 것이 필요하다. 본 연구에서 사용한 개별요소법(DEM)은 입자의 마찰력 및 항력을 제외한 반발력과 인장력만을 적용하였다. 초기 쿼드트리(Quad-tree)형식으로 충진된 입자들을 DEM을 이용하여 재배치할 경우 입자의 형상이 원형이기 때문에 입자사이에 존재하는 빈 공간을 최소화 할 수 있다. 결국 입자 중심점의 배치가 정삼각형에 가깝게 되는 특징을 보여준다. 이 재배치된 입자를 대상으로 Delaunay 삼각기법을 이용하여 삼각망을 구성하고, Laplace 보간을 수행하여 격자 품질을 향상시켰다. Laplace 보간 전 후의 형상비(Aspect Ratio: AR)를 비교한 결과 DEM을 이용하여 작성한 격자의 품질도 우수하지만, Laplace보간을 수행한 이후 보다 높은 품질의 격자가 생성되는 것을 확인하였다. 본 연구에서 개발한 기법은 기존의 삼각격자망 생성기법에 비해 다소 계산시간이 오래 걸리는 단점이 있지만, 복잡한 형상과 정확한 지형의 재현을 필요로 하는 파랑 해석용 유한요소 격자망 작성 및 다양한 수치모의 분야에서 그 적용 가능성이 매우 높다고 사료된다.