• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.480-483
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• 2005

A roll forming process is developed for an automotive part of high strength steel. Forming rolls are designed through the plane strain elastic-plastic finite element analysis to estimate the springback. It is assumed that the process can be approximated as a series of multi-step bending processes. Then the 3D elastic-plastic finite element analysis with the solid element is carried out for the designed roll forming process. The prototype roll forming machine and the forming rolls are made and the experiments are carried out. The results of the analysis and the experiments are compared.

• Journal of Advanced Marine Engineering and Technology
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• v.18 no.4
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• pp.69-76
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• 1994

Thermal elasto-plastic analysis of axi-symmetric body by the finite element method is presented in this paper for analyzing the process of upset forming of circular section extruded bar. The example of calculation for upset forming of Nimonic extruded bar is also presented. It is shown that remeshing of quadrilateral finite element is necessary because the very highly distorted element by plastic deformation disturbs the calculation. Calculated values for nodal points in new mesh are obtained from nodal points of old mesh by linear interpolation method. The experimental results are compared with calculated values. The appearance of upsetupset forming obtained by experimental method is very similar to that obtained by calculations. So, it is proved that the thermal elasto-plastic analysis of axi-symmetric body by the finite element method is very useful for finding the optimum upsetting condition.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.3
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• pp.33-38
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• 2000

In process of tube spinning far shock absorber on vehicles, the selection of feed rate and rounding radius of forming roller and revolution speed of tube and forming roller, forming gap between die and forming roller are very important factors to obtain the optimal process result. In this paper, rigid-plastic FEM and UBET analysis are applied to verify effect of each factors by forming load. We can obtain the optimal conditions to prevent defects during processing.

• Transactions of Materials Processing
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• v.12 no.2
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• pp.83-87
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• 2003

Current state of plastic processes of steel bearing parts is surveyed. According to the advances in plastic forming technologies and their great advantage to mass production, plastic processes are adopted in manufacturing majority of bering parts. The rings are forged or ring rolled and the rolling elements, i.e, balls or rollers are cold formed before fine machining. Bearing's steel retainers are mainly press formed using cold rolled seel strips. Including the general explanation about above processes, some details of forging technology, control of forging temperature and after cooling process, and examples of computer simulation are described.

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.1136-1141
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• 2003

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, comer 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 crack during rolling and sintering processes.

• Transactions of Materials Processing
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• v.7 no.3
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• pp.233-245
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• 1998

A new approach has been proposed for the incremental analysis of the nonsteady state large deformation of planar anisotropic elastic-plastic sheet forming. A mathematical brief review of a constitutive law for the incremental deformation theory has been presented from flow theory using the minimum plastic work path for elastic-plastic material. Since the material embedded coordinate system(Lagrangian quantity) is used in the proposed theory the stress integration procedure is completely objective. A new return mapping algorithm has been also developed from the general midpoint rule so as to achieve numerically large strain increment by successive control of yield function residuals. Some numerical tests for the return mapping algorithm were performed using Barlat's six component anisotropic stress potential. Performance of the proposed algorithm was shown to be good and stable for a large strain increment, For planar anisotropic sheet forming updating algorithm of planar anisotropic axes has been newly proposed. In order to show the effectiveness and validity of the present formulation earing simulation for a cylindrical cup drawing and front fender stamping analysis are performed. From the results it has been shown that the present formulation can provide a good basis for analysis for analysis of elastic-plastic sheet metal forming processes.

• Transactions of the Korean Society of Automotive Engineers
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• v.3 no.3
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• pp.19-28
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• 1995

The explicit scheme for finite element analysis of sheet metal forming problems has been widely used for providing practical solutions since it improves the convergency problem, memory size and computational time especially for the case of complicated geometry and large element number. The explicit schemes in general use are based on the elastic-plastic modelling of material requiring large computation time. In the present work, rigid-plastic explicit finite element method is introduced for analysis of sheet metal forming processes in which plane strain normal anisotropy condition can be assumed by dividing the whole piece into sections. The explicit scheme is in good agreement with the implicit scheme for numerical analysis and experimental results of auto-body panels. The proposed rigid-plastic explicit finite element method can be used as robust and efficient computational method for prediction of defects and forming severity.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.393-398
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• 1999

The plastic instable flow phenomenon happens in practical forming process, I. e. upsetting, backward extrusion, piercing, indentation. And also, it is difficult to control precisely the shape and dimensions of forming process. It is found that instabilities of the process are mainly connected with imperfections in the lubrication, billet eccentricity, inclined punch alignment. In view of the direct relationship between instable material flow and quality defects of the products and for better control of forming operation, we should necessarily find out their phenomena. In this study, we introduced the friction disturbance due to inclined punch angle. Analysis of upset forging is carried out using the rigid plastic FEM and slab method with eccentricity. Also, we considered the buckling parameters of billet with the large aspect ratio in upset forging.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.66-69
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• 2002

In the ideal forming theory(1), which has been deviously developed as a direct method for optimizing forming process, material elements are required to deform following the minimum plastic work path (or the proportional true strain path). Besides the general theory(2,3), specific ideal forming theories have been developed for membrane sheet forming(4) as well as two-dimensional steady bulk forming(5-7). In this work, the ideal forming theory was successfully applied for non-steady bulk forming under the plane strain condition. Here, the shape change complying with the minimum plastic work path, was effectively described by developing a numerical code based on the characteristic method. Numerical results obtained for a specific industrial part also include the optimum pre-forming shape and its evolving shape change to the final shape as well as the boundary traction history.