• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.44-49
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• 2008

The characteristic of magnesium alloy is the most light in utility metal, the effect of electromagnetic wave interception, excellent specific strength and absorptiveness of vibration. Although magnesium alloy with above characteristic is a subject matter which is suitable in world-wide tendency of electrical component frame, sheet magnesium alloy is difficult to process. Therefore, forming analysis of sheet magnesium alloy and applying warm-working to process are indispensable. Among Finite element method, the static implicit finite element method is applied effectively to analyze sheet magnesium alloy stamping process, which include the forming stage. In this study, it was focused on the crack, wrinkling and spring back on sheet magnesium alloy stamping by the static implicit analysis. According to this study, the result of simulation will give engineers good information to access the forming technique on sheet magnesium alloy. And its application is being increased especially in the production of electrical component frame for the cost reduction, saving of defective ratio, and improvement of Productivity.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.149-153
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• 2008

Since magnesium alloy sheets have been employed in industrial field which requires the light weight and thin engineering components, most of researches have been focused on the formability of magnesium ahoy sheet. In warm press forming of magnesium alloy sheet, it is important to control the sheet temperature by heating the sheet in closed die. When forming a commercial AZ31 magnesium alloy sheets which are 0.5mm and 1.0mm thick, respectively, time arriving at target temperature and temperature variation in magnesium alloy sheet have been investigated. Sheet metals were mostly formed in simple shapes such as circular or rectangular. Few studies about forming of complex shapes were reported. Thus, the formability of magnesium alloy sheet for complex shapes is investigated. The process variable for a double sink shape deep drawing with circular and rectangular shape was investigated by varying temperature, velocities, and clearances. Accordingly, temperature, velocities, and clearances suitable for forming were suggested through investigating the thickness variation of the product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.53-56
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• 2004

The mechanical properties and optical micrographs are studied for rolled magnesium alloy sheet with hexagonal close packed structure(HCP) at room and elevated temperatures. Tensile properties such as tensile strength, elongation, R-value and n-value are also measured for AZ31 magnesium alloy. Magnesium with strong texture of basal plane parallel to the rolling direction usually has high R-value and plastic anisotropy at room temperature. As temperature increases, the R-value for AZ31 magnesium sheet decreases. In addition, the AZ31 sheet becomes isotropy and recrystallization above $200^{\circ}C$. Formability of magnesium alloy sheets remarkably poor at room temperature is improved by increasing temperature. Sheet forming of magnesium alloy is practically possible only at high temperature range where plastic anisotropy disappears.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.337-340
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• 2008

Magnesium alloy is expected to be widely used for mobile electronic appliances as well as automobile parts for its lightweight and EMI-shielding characteristics. In the present investigation, a Note-PC upper case made of magnesium alloy AZ31 sheet was developed by using the press forming technology at elevated temperature. Considering the press forming process and the formability of magnesium alloy sheet, the case shape and the press die was designed. The optimum forming condition was experimentally examined. Then the as-received magnesium alloy sheet was press-formed into the designed case shape under the optimum forming condition.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.586-593
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• 2008

In warm press forming of magnesium alloy sheet, it is important to control the sheet temperature by heating the sheet in closed die. When forming a commercial AZ31 magnesium alloy sheets which are 0.5mm and 1.0mm thick, respectively, time arriving at target temperature and temperature variation in magnesium alloy sheet have been investigated. The deep drawing process with rectangular shape alone at the first stage and with both circular and rectangular shapes at the second stage was employed. At the first stage, through deep drawing process with rectangular shape alone according to various forming temperature($150{\sim}350^{\circ}C$) and velocity($0.1{\sim}1.0mm/s$), optimum forming condition was obtained. At the second stage, deep drawing process with the circular and rectangular shapes were performed following deep drawn square cups with Limited Drawing Height(LDH) obtained at the first stage. Here, clearance which is defined a gap between the die and the punch including sheet was set to ratio of 20, 40 and 100% to thickness in sheet. Accordingly, temperature, velocities, and clearances suitable for forming were suggested through investigating the thickness variation of the product.

• Transactions of Materials Processing
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• v.23 no.8
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• pp.495-500
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• 2014

Magnesium alloys are currently expected to be widely used for weight reduction of cars and as high efficient materials in the automotive and electronics industries. Although the specific strength of magnesium is excellent, it cannot be easily formed at room temperature due to its HCP structure. However in order to improve the formability of magnesium, it is necessary to investigate its formability in the warm temperature range. In the current study, the aim was to add to the magnesium property database so that the mass production of a magnesium car body can be accomplished. Warm tensile tests were conducted and the forming limit diagram was determined to confirm formability characteristics of magnesium AZ31B alloy sheet. In addition the bending formability and the magnesium damping capacity were evaluated for AZ31B and compared to SPRC440E which is a sheet steel used for car bodies.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.5
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• pp.519-524
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• 2014

The use of light weight magnesium alloy offers significant potential towards improvement of the automotive fuel efficiency. However, the application of formed magnesium alloy components in auto-body structures is restricted due to the low formability at room temperature and lack of knowledge for processing magnesium alloys at elevated temperatures. In this study, a warm tensile test of magnesium alloys was performed to measure tensile strength and elongation. An improvement in formability was confirmed at increased temperatures above about $250^{\circ}C$. Car body warm forming technology was conducted for forming forming reinforced dash components of the magnesium alloy AZ31B sheet at elevated temperatures.

• Transactions of Materials Processing
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• v.18 no.2
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• pp.112-115
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• 2009

Press forming of magnesium alloy sheet is conducted at elevated temperatures to improve the press formability due to its low formability at room temperature. At elevated temperatures, magnesium alloy sheet formability is known to be very sensitive to the strain rate. In this paper, warm deep drawing tests of magnesium alloy AZ31 sheet was conducted under double forming velocity as well as single forming velocity to examine the formability change by forming velocity profile. The observed formability improvement by double forming velocity was analyzed by using the finite element analysis.

• Transactions of Materials Processing
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• v.17 no.6
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• pp.412-419
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• 2008

Using lightweight materials in vehicle manufacturing in order to reduce energy consumption is one of the most effective approach to decrease pollutant emissions. As a lightweight material, magnesium is increasingly employed in automotive parts. However, because of its hexagonal closed-packed(HCP) crystal structure, in which only the basal plane can move, the magnesium alloy sheets show low ductility and formability at room temperature. Thus the press forming of magnesium alloy sheets has been performed at elevated temperature within range of $200^{\circ}C{\sim}250^{\circ}C$. Here we try the possibility of sheet metal forming at room temperature by adopting incremental forming technique with rotating tool, which is so called as rotational-incremental sheet forming(RISF). In this rotational-incremental sheet forming the spindle tool rotates on the surface of the sheet metal and moves incrementally with small pitch to fit the sheet metal on the desired shape. There are various variables defining the formability of sheet metals in the incremental forming such as speed of spindle, pitch size, lubricants, etc. In this study, we clarified the effects of spindle speed and pitch size upon formability of magnesium alloy sheets at room temperature. In case of 0.2, 0.3 and 0.4mm of pitch size with hemispherical rotating tool of 6.0mm radius, the maximum temperature at contact area between rotating tool and sheet metal were $119.2^{\circ}C,\;130.8^{\circ}C,\;and\;177.3^{\circ}C$. Also in case of 300, 500, and 700rpm of spindle speed, the maximum temperature at the contact area were $109.7^{\circ}C,\;130.8^{\circ}C\;and\;189.8^{\circ}C$.

• Journal of Welding and Joining
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• v.31 no.3
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• pp.49-53
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• 2013

Recently, studies about application of magnesium alloy sheet to automotive bodies are on the increase. For application to automotive bodies, researches about characteristics of resistance spot welding of magnesium alloy sheet are essential. Electrode life of resistance spot welding of magnesium alloy is very short due to sticking of magnesium alloy to copper alloy electrode. To increase electrode life, most effective method is inserting cover plate between electrode and magnesium sheet. But application of cover plate to actual process is difficult and decreases welding productivity. Process tape supplied automatically as cover plate can minimize lose of productivity and increase welding quality. In this study, resistance spot welding of magnesium alloy is carried out with applying process tape. Acceptable welding current region according to electrode force and welding time is determined.