• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.9
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• pp.1451-1456
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• 2003

In code roll forming processes, the sheet metal strip is gradually and successively bent into a desired profile. Occurrence of buckling is one of the major defects. Buckling may occur due to longitudinal stress and it is difficult to predict buckling behavior. In this study an analytical method for buckling behavior during roll forming is proposed. All numerical simulations are performed by finite element analysis. The behavior of buckling can be predicted with the simulation modeling of the finite element method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.10
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• pp.2082-2088
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• 2002

Among various methods to manufacture the PDP barrier ribs, the pressing and the roll forming methods are simple and economical because they form the ribs by utilizing the plastic flow of the green tape in a relatively short time without generating air-polluting dusts. In the present study, the roll forming method was investigated by experiments as well as numerical analyses and in result the groove roll and the preform were designed. The effect of draft angle, corner radius, and initial thickness of the green tape on the plastic flow was examined by a series of parametric studies. The preform was recommended to ease the plastic flow into the grooves and to avoid the occurrence of cracks during rolling and sintering processes.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.5
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• pp.800-805
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• 2013

Incremental forming of sheet metal is a modern method of forming sheet metal, where parts can be formed without the use of dedicated dies. Existing experimental configurations for incremental forming can be broadly classified into two categories, i.e., negative and positive forming. In this paper, forming qualities such as shape accuracy and surface roughness of Al 1050 material were discussed for different forming methods. The formed and the corresponding opposing surfaces were measured with a three-dimensional scanner and a surface roughness tester. It was found that in terms of shape accuracy, the best opposing surface was obtained with positive forming, whereas the worst formed surface was obtained with negative forming; furthermore, the opposing surface is always better than the formed surface, regardless of the forming method used.

• Journal of the Korean Society of Propulsion Engineers
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• v.10 no.4
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• pp.34-39
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• 2006

The flow forming has been used to produce long thin walled tube parts, with reduced forming force and enhanced mechanical for a good finished part, compared with other method formed parts. Especially, the flow forming is suitable for making high precision thin walled cylinders, such as rocket motor cases, combustion chamber, hydraulic cylinders and high-pressure vessels and so on. In this paper, finite element analysis of three-roller forward and backward flow forming for combustion chamber is carried out to study effects of forming depth and feed rate on forming force. The axial and radial forming forces of forward flow forming on several forming depth and feed rate conditions are compared with those of backward flow forming.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.10
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• pp.941-948
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• 2017

Recently, hydrogen energy has been in the spotlight as an alternative to diminishing fossil fuels and as a potential solution to environmental pollution. The development of hydrogen-fueled vehicles and the demands for improved fuel efficiencies have resulted in the need to increase the volume of the hydrogen pressure vessels. Pressure vessels having an elliptical bottom, as opposed to one that is hemispherical, allow for a greater capacity. However, there are insufficient studies on the feasibility of the forming process required for an elliptical bottom. In this study, the liner capacity is calculated according to the ratios of the major to the minor axes of the elliptical bottom part in a hydrogen pressure vessel. Structural safety is verified through finite element analyses, and the results are compared to the theoretical results. The feasibility of the proposed elliptical shape of the pressure vessel bottom, while filled to maximum capacity, is validated through forming analysis.

• Journal of the Korean Society of Propulsion Engineers
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• v.9 no.4
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• pp.16-22
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• 2005

The flow forming has been used to produce long thin walled tube parts, with reduced forming force and enhanced mechanical and surface quality for a good finished part, compared with other method formed parts. So flow forming technique is used widely in industrial production. Especially spinning and flow forming techniques are used frequently in automotive, aerial, defense industry. In this paper, finite element method analysis of three-roller backward flow forming of a workpiece is carried out to study effects of forming depth and feed rate on forming force. The axial and radial forces on several forming depth and feed rate conditions are obtained.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.3
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• pp.339-344
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• 2013

Hot forming using boron steel is currently used for manufacturing low-weight automobile body parts, and a high tensile strength of about 1,500 MPa is obtained after hot forming. However, a high fatigue life is a more important factor than high strength when it is used for automobile suspension parts. A tubular torsion beam axle (TTBA) is one of these suspension parts, and this research deals with the fatigue characteristic of TTBA using hot forming. The low cyclic fatigue life of boron steel is investigated according to the cooling method. In addition, a structural and fatigue analysis of TTBA is performed to predict the fatigue life. The stress concentration that occurs in the tubular torsion beam is found, and the longest fatigue life occurs when rapid cooling is utilized in the TTBA fabrication.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.9
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• pp.1073-1080
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• 2012

Incremental forming is a cold working process in which a small part of the material is being deformed and the area of local deformation is moving over the entire material. In this paper, we study description schemes to perform finite element analysis for the incremental forming. The selected description schemes to examine are the Lagrangian description and the arbitrary Lagrangian-Eulerian (ALE) description. The sliding boundary scheme coupled with ALE is also examined to overcome the distortion problems of elements on the contact surface. Results show that the ALE description with the sliding boundary scheme is most favorable in overcoming the distortion of elements. This description leads to make the simulation continued to the final stage of the incremental forming. On the other hand, the Lagrangian description as well as the original ALE description makes the elements much distorted and the analysis is stopped long before arriving at the final shape of deformation.

• Design & Manufacturing
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• v.16 no.4
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• pp.24-33
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• 2022

Fiber-reinforced plastics(FRPs) have excellent specific stiffness and strength, so they are usually used as automotive parts that require high rigidity and lightweight instead of metal. However, it is difficult to predict the mechanical properties of injection molded parts due to the fiber orientation and breakage of FRPs. In this paper, the fiber orientation characteristics and mechanical properties of injection molded specimens were evaluated in order to fabricate automotive transmission side covers with FRPs and design a rib structure for improvement of their rigidity. The test molds were designed and manufactured to confirm the fiber orientation characteristics of each position of the injection molded standard plate-shaped specimens, and the tensile properties of the specimens were evaluated according to the injection molding conditions and directions of specimens. A gusset-rib structure was designed to improve the additional structural rigidity of the target products, and a proper rib structure was selected through the flexural tests of the rib-structured specimens. Based on the evaluation of fiber orientation and mechanical characteristics, the optimization analyses of gate location were performed to minimize the warpage of target products. Also, the deformation analyses against the internal pressure of target product were performed to confirm the rigidity improvement by gusset-rib structure. As a result, it could be confirmed that the deformation was reduced by 27~37% compared to the previous model, when the gusset-rib structure was applied to the joining part of the target products.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.1
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• pp.132-141
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• 1998

A parallel version of sheet forming analysis program was developed. This version is compatible with any parallel computers which support MPI that is one of the most recent and popular message passing libraries. For this purpose, SERI-SFA, a vector version which runs on Cray Y-MP C90, a sequential vector computer, was used as a source code. For the sake of the effectiveness of the work, the parallelization was focused on the selected part after checking the rank of CPU consumed from the exemplary calculation on Cray Y-MP C90. The subroutines associated with contact algorithm was selected as targe parts. For this work, MPI was used as a message passing library. For the performance verification, an oil pan and an S-rail forming simulation were carried out. The performance check was carried out by the kernel and total CPU time along with theoretical performance using Amdahl's Law. The results showed some performance improvement within the limit of the selective paralellization.