• Journal of the Korean Society for Precision Engineering
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• v.26 no.5
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• pp.57-63
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• 2009

Interface friction in blanking dies, cold forging and extrusion of aluminum alloys is a major cause of inefficient process. This paper describes an investigation of femtosecond laser texturing for reduction of interface friction on sliding surfaces in forming process. Femtosecond direct writing technology was used to fabricate a laser micro-machined die and to create microgroove patterns with varying size and density on metal forming dies. A systematic approach to find the optimum parameters and computer simulation comparison of friction coefficients are provided to study the relation of friction coefficients and die profiles. In metal forming tests, the effectiveness of various laser-machined patterns for enhancing interface lubrication is determined.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.45-48
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• 1999

A program for initial blank design in sheet forming which contains the capabilities of forward loading simulation by the finite element method and backward tracking simulation has been developed and proved the effectiveness by applying to a square cup stamping process. In the blank design of square cup stamping the backward tracing program can produce an optimum blank configuration which forms a sound net-shape cup produce without machining after forming. Another general application appears in the blank design of a cup stamping with protruding flanges one of typical automobile components. The blank configurations derived by backward tracing simulation have been confirmed by a series of loading simulations. The approach for decision of an initial blank configuration presented in this study will be a milestone in fields of sheet forming process design.

• Transactions of Materials Processing
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• v.32 no.5
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• pp.276-286
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• 2023

The field of sheet metal forming using press technology has become essential in modern mass production systems. Draw bead is often used to enhance formability. However, optimal draw bead design often requires excessive time and cost due to iterative experimentation and sometimes results in some defects. Given these challenges, there is a need to enhance formability by introducing segmented blank holders without draw beads. In this paper, the feasibility of a localized holding strategy using segmented blank holders is evaluated without the use of draw beads. The possibility for improving the formability was evaluated by utilizing a combination of the forming limit diagram and the wrinkle pattern-based defect indicators. Artificial neural networks were used for predicting defect indicators corresponding to arbitrary input holding forces and the NSGA-II optimization algorithm is used to find optimum blank holder forces yielding better defect indicators than the original process with drawbeads. Using optimum holding forces obtained from the proposed procedure, the stamping process with the segmented blank holders can yield better formability than the conventional process with drawbeads.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.373-376
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• 2006

The ring rolling design for a large-scale Ti-6Al-4V alloy ring was performed with a calculation method and FEM simulation. The ring rolling design includes geometry design and optimization of process variables. The calculation method was to determine geometry design such as initial billet and blank size, and final rolled ring shape. A commercial FEM code, SHAPE 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, 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.10a
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• pp.141-148
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• 1994

In order to improve the productivity of cold forging at low production cost, an integrated system's approach is necessary in handling the material preparation and the optimum process design, considering the forming machines, tooling, and operation including quality control. As the first step toward this approach, an expert system for multi-stage cold forging process design for fasteners with various head geometries is developed using Prolog language on IBM 486 PC. For effective representation of the complex part geometries, the system uses the multiple element input, and the forward inference scheme in determination of the initial billet size and intermediate forging steps. In order to determine intermediate steps, the basic empirical rules for extrusion, heading, and trimming were applied. The required forming loads and global strain distributions at each forging step were calculated and displayed on the PC monitor. The designed process sequence drawing can be obtained by AutoCAD. The developed system will be useful in reducing trial and error of design engineers in determining the diameter and height of the initial cylindrical billet from the final product geometry and the intermediate necessary sequences.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.06a
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• pp.55-60
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• 2006

Draw-bead is applied to control the material flow in a stamping process and improve the product quality by controlling the draw-bead restraining force (DBRF). Actual die design depends mostly on the trial-and-error method without calculating the optimum DBRF. Die design with the predicted value of DBRF can be utilized at the tryout stage effectively reducing the cost of the product development. For the prediction of DBRF, a simulation-based prediction model of the circular draw-bead is developed using the Box-Behnken design with selected shape parameters such as the bead height, the shoulder radius and the sheet thickness. The value of DBRF obtained from each design case by analysis is approximated by a second order regression equation. This equation can be utilized to the calculation of the restraining force and the determination of the draw-bead shape as a prediction model. For the evaluation of the prediction model, the optimum design of DBRF in sheet metal forming is carried out using response surface methodology. The suitable type of the draw-bead is suggested based on the optimum values of DBRF. The prediction model of the circular draw-bead proposes the design method of the draw-bead shape. The present procedure provides a guideline in the tool design stage for sheet metal forming to reduce the cost of the product development.

• Transactions of Materials Processing
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• v.1 no.1
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• pp.87-94
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• 1992

An analytical method has been presented for the study of the superplastic bulging process of sheet metal. Through this method, it is possible to obtain the optimum pressure-time curve for the superplastic forming and to predict the thickness distribution of bulged sheet metal with less computational cost than that by finite element analysis. Experiments have been performed to confirm the results of this analysis with Supral 150 sheets by adopting the computed optimum pressure-time curve. Good agreement between predictions and experimental data has been obtained for the bulged profile and its thickness distribution.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.95-101
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• 1998

The steel door inner was manufactured via a new route, tailored blanking process, to remove hinge reinforcement parts, using thicker panels laser welded, instead. It is very important, first of all, in this process, to design optimum configuration of tailored blanks and determine the optimum process control for the stamping. Generally, it was found that the severe deformation reduction behavior during stamping in the thinner panel around weld line caused cracks and the other troubles in formability. It is our purpose of this investigation to introduce how the process control parameters, such as tailored blank configuration, size, location in the die, the position of weld line, BHF, bead configuration, work on the formability. In addition, causes of cracks and movement of weld line after forming were analyzed and compared with computer simulation work.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.17-24
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• 1998

This paper deals with the springback characteristics of cold rolled sheet steel through the use of the V-bending process and U-bending one. The influence of material properties on the springback of forming processes was investigated. In the V-bending process there was an optimum bend radius for each combination of parameters which produced minimal springback. In the U-bending process the blank holder force can control the degree of springback. A high blank holding force resulted in a uniform strain distribution and reduced the level of springback.

• Transactions of Materials Processing
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• v.20 no.1
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• pp.42-47
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• 2011

Recently, with the merits of simplicity, ease of mass production and cost effectiveness, a roll-to-roll (R2R) forming process is tried to be employed in the manufacturing of the circuit board, barrier ribs and other electronic device. In this study, the roll-to-roll process for the forming of micro-pattern in electronic device panel is designed and analyzed. In the preliminary experiments, two major defects, i.e., crack near the dimple wall and wrinkling on outside region of dimple, are found. The study on the crack prevention is carried out in previous works by authors. In this study, the cause of wrinkling and modification of tooling to prevent the wrinkling is studied. The main cause of wrinkling is considered to be the uneven material flow along the rolling direction. To reduce or to retard the wrinkling initiation, a dummy shape on outside the pattern is introduced. From the finite element analysis results, it is shown that the dummy shape can reduce the uneven material flow significantly. Finally the effect of dimensions of the dummy shape on material flow is investigated and the optimum dimensions are found.