• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2000.10a
• /
• pp.143-148
• /
• 2000

This paper describes how to make tailored blanks of front side member that were composed of high strength steel and TRIP(TRansformation Induced Plasticity) steel for weight reduction and improvement of crash load. Tailored blanks made by laser and mash-seam welding were compared with non-tailored blanks made by spot welding. Static compression tests were performed for performance comparison of each sample. Front side members made by tailored blank were superior to those made by spot welding in the initial, but those results were inverse in the last. Average load of tailored blank in six-angle type was better than that of rectangular type.

• Transactions of Materials Processing
• /
• v.10 no.3
• /
• pp.200-205
• /
• 2001

This paper describes how to make tailored blanks of front side member that were composed of high strength steel and TRIP(TRansformation Induced Plasticity) steel for weight reduction and improvement of crash load. Tailored blanks made by laser and mash-seam welding were compared with non-tailored blanks made by spot welding. Static compression tests were performed for performance comparison of each sample. Front side members made by tailored blank were superior to those made by spot welding in the initial, but those results were inverse in the last. Average load of tailored blank in six-angle type was better than that of rectangular type.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2007.10a
• /
• pp.223-227
• /
• 2007

New forming technologies are being introduced to automotive manufacturing processes. Among them, a simultaneous forming is one of the innovative forming technologies to be able to reduce production time and cost. Several parts can be simultaneously manufactured by the process, while the conventional stamping demands the same number of die sets with the number of parts. In this study, the automotive rear floor side member was manufactured by the simultaneous forming. The position and the size of initial blank were determined by forming analyses and try-outs, and the blank movement during the forming was controlled by introducing the spotweld.

• Transactions of Materials Processing
• /
• v.9 no.6
• /
• pp.574-581
• /
• 2000

A vertically-walled auto-body part is one of the most difficult stamping parts because of angle change, wall curl, and twisting of the blank after springback as well as fracture and wrinkle. In this study, computational simulations of the vertically-walled auto-body part are carried out focusing on angle change, wall curl, and twisting after springback. Binderwrap blank shape is used in forming analysis for precise initial contacts between punch and blank. An adaptive mesh method is used in springback analysis for precise calculation of bending moments. In springback analysis, the differences of 2 and 3 dimensional analysis are compared and the effects of blank holdig force and friction coefficient are evaluated. In order to verify the validity of simulation results, they are compared with measured ones. The predicted thickness distribution and formed shape are agreed well with those of the measurement. The Predicted springback amount is less than that of the measurement.

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

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.20 no.6
• /
• pp.1810-1818
• /
• 1996

A new finite elemetn approach is introduced for direct prediction of bland shapes and strain distributions from desired final shapes in sheet metal forming. The approach deals with the geometric compatibility of finite elements, plastic deformation theory, minimization of plastic work with constraints, and a proper initial guess. The algorithm developed is applied to cylindrical cup drawing, square cup drawing, and fron fender forming to confirm its validity by demonstratin reasonable accurate numerical results of each problems. Rapid calculation with this algorithm enables easy determination of various process variables for design of sheet metal forming process.

• Journal of Ocean Engineering and Technology
• /
• v.13 no.2 s.32
• /
• pp.11-17
• /
• 1999

The objective of this paper is to introduce very fast but still stable solution using finite element procedures, and it has been used in an iterative mode for product design applications. A lot of numerical techniques have been developed to deal with the material, geometric and boundary condition non-linearities occurred in the stamping process. One of them, the One-Step FEM is very efficient and useful tool for a design and trouble-shooting in various stamping processes. In this method, the mathod, the material is assumed to deform directly from the initial flat blank to the final configuration without any intermediate steps. The formulation is based on the deformation theory of plasticity and the upper bound theorem. As a result of the calculations, the initial blank shape is obtained, together with the material flow, strains and thickness distribution in the part.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.1 no.1
• /
• pp.140-148
• /
• 1993

When a large automobile sheet metal part is formed in a draw die, the binder wrap is first calculated to predict the initial punch contact location for avoiding wrinkles and severe stretching of its thin blank sheet. Since the boundary of a pseudo blank in calculating a binder wrap by means of a geometrically nonlinear finite element method is unknown in advance, an iteration method is generally used. This paper presents an effective iteration method for correction of the pseudo blank in a binder wrap calculation. For the performance test, two examples are adopted. The calculated results for both examples show the good convergence which wasted solutions are obtained in the second iteration step.

• Journal of Welding and Joining
• /
• v.15 no.2
• /
• pp.54-63
• /
• 1997

For the purpose of establishing laser welding condition (laser power, welding speed and beam focus) and of evaluating tailored blanks for two kinds of thin steel sheets SPCC and SK5M using in the thin plate structure such as automobile, train, and so on, investigated their $CO^2$ laser weldability under various initial welding conditions. SPCC thin sheet showed good weldability under some welding conditions. But, high carbon steel sheet SK5M needed heat treatment after welding to obtain ductility of the welded joint. And next, tailored blank was tested through deep drawing to evaluate reliability of their obtained laser welding conditions. The forming depths by tailored blank were SPCC+SPCC=22-25mm and SK5M+SK5M=13-25mm.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1997.10a
• /
• pp.65-71
• /
• 1997

Computer simulations and test trials are carried out to get the optimal conditions about the stamping die design of the tailor laser welded automotive door inner. Firstly, the stamping process including gravity deflection, bead calibration, binder wrap, forming and spring back, are analyzed by the computer simulation. The results of simulation shows good correspondance with those of test trial under the same conditions. The variables of parametric study which will be investigated in the simulation and test trials, are determined form the results of the first run. The formability under the various conditions is evaluated, which are the initial postion of blank, blank holding force, corner radius and the shape of drawbead. Finally, well controled sound product without fracture, wrinkling and excessive weldline movement is obtained.