• Design & Manufacturing
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• 제18권2호
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• pp.29-34
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• 2024

This study intends to reduce forming load by adding die rotation to flange-upsetting process. Materials arc formed by the compression and rotational torque which are accrued from rotation of the lower die accompanied by axial compression of the punch. For the theoretic analysis of flange-upsetting process using rotation die, slab method was used. Furthermore, for the verification of the theoretic analysis results, FEM simulation using DEFORM 3D a commercial software was done, and through the model material experiment using Prasticine, the results were compared and reviewed. Flange-upsetting process using rotation die shows reduced forming load compared with process without die rotation and demonstrates uniform distribution of strain. And as for the effect of the reduction of forming load, the less the aspect ratio(h₀/d₀) and the greater friction coefficient, the greater effect is. With increase in die rotation velocity, the effect of forming load reduction also increases little by little, but its effect on forming load reduction is very negligible compared with other forming parameters. Theoretic analysis results and simulation results coincided pretty well. The flange-upsetting process using die rotation are evaluated as useful process that can produce reduction of forming load and uniform strain.

• 한국시뮬레이션학회논문지
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• 제8권2호
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• pp.73-85
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• 1999

In this paper, the productivity estimation of the painting line in an automobile plant is studied. To improve the bottleneck and the weak point of the process, computer simulations are performed. In determining the system specification, the status of the conveyor lines and the other physical facilities are considered in order not to intervene with each other and to satisfy the painting facility restrictions. As simulation parameters, production performance ratio, number of hanger and dolley, down time, speed of conveyor and the pitch of a painting body are chosen on the basis of exhaustive field evaluation to study their effects on the capacity of the process. The results of the simulation show that we can improve the capability of they system without additional investment to the plant facility. The best condition for the maximum capacity of the process is selected by comparing the alternative computer simulation results. As a simulation language, Promodel is used which is very useful and easy to use in manufacturing oriented simulation.

• 소성∙가공
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• 제15권1호
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• pp.15-20
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• 2006

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filling difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation for both the conventional molding and the RTR molding processes.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 금형가공,미세가공,플라스틱가공 공동 심포지엄
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• pp.9-12
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• 2005

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filing difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation fur both the conventional molding and the RTR molding processes

• 품질경영학회지
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• 제12권1호
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• pp.17-30
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• 1984

A computer method is developed for group technology layout and its simulation analysis. The method is composed of three phases: Phase I sorts the parts by its similar production routes and forms part families. Phase II plots the layout by machine cell and evaluates the group layout alternatives by the total process time analysis and the part travel distance evaluation analysis. Phase III also evaluates the alternatives by simulation analysis using SIMAN simulation software. All the computer programs are developed with BASIC except SIMAN simulation.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1999년도 춘계학술대회논문집
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• pp.207-212
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• 1999

A computational method based on the three-dimensional finite element method is developed for the deformation analysis of roll forming process. the method approximates the process as a kinematically steady state deformation of strip. For industrial usefulness of the simulation method several rolls with arbitrary shapes in one stand can be considered. The shapes and the thickness distributions of strip after roll forming were examined by comparing computation results with experiments It is concluded that the tool is useful enough to predict the process. The overall simulation method was integrated into a sorftware package to help the industrial roll-design.

• 한국시뮬레이션학회논문지
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• 제4권1호
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• pp.87-97
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• 1995

Simulation techniques are used to improve the productivity of a textile factory. A simulation model is developed for the analysis of investment for dyeing process equipment, such as dryers and bleachers. For modeling and analysis, AIM (Analyzer for Improving Manufacturing) is used. AIM is a manufacturing oriented simulation software developed by Pritsker Corp. AIM provides interactive model building and simulation, automatic animation, and powerful graphic outputs. thereby, drastically reducing modeling efforts and also enhancing communication capabilities.

• 한국시뮬레이션학회논문지
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• 제8권1호
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• pp.19-33
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• 1999

The fundamental issues to evaluate machine tools performance through simulation pertain to the physical models of the machine tool itself and of process while the practical problems are related to the development of the modular software structure. It allows the composition of arbitrary machine/process models along with the development of programs to evaluate each state of machining process. Surface roughness is one of the fundamental factors to evaluate machining process and performance of machine tool, but it is not easy to evaluate surface roughness due to its tribological complexity. This paper presents an algorithm to calculate surface roughness considering cutting geometry, cutting parameters, and contact dynamics of cutting between tool and workpiece as well as tool wear in turning process. This proposed algorithm could be used in the designed virtual machining system. The system can be used to evaluate the surface integrity of a turned surface during the design and process planning phase for the design for manufacturability analysis of the concurrent engineering.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 추계학술대회 논문집
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• pp.81-84
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• 2001

An inverse finite element approach is employed for more capability to design the optimum blank shape from the desired final shape with small amount of computation time and effort. In some drawing or stamping simulation with inverse method, it is difficult to apply inverse scheme due to the large aspect ratio or steep vertical angle of inclination. The reason is that initial guesses are hard to make out with present method for those cases. In this paper, a direct mesh marring scheme to generate initial guess on the sliding constraint surface described by finite element patches is suggested for one step inverse analysis to calculate initial blank shape. Radial type mapping is adopted for the simulation of rectangular cup drawing process with large aspect ratio and parallel type mapping for the simulation of S-Rail forming process with steep vertical angle of inclination.

• 소성∙가공
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• 제7권6호
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• pp.586-593
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• 1998

In recent automotive industries there has been significant increase in applications of computer simulation to the manufacturing of stamping dies for inner and outer body panels which greatly affect durability and aesthetic quality of automobiles. Enhancement of die quality and reduction of total die manufacturing time and consequently manufacturing cost are the visible outcome. However to successfully apply the result of simulation by a commercial package to the die manufacturing development of an optimal die manufacturing process is required upon the completion of analysis of forte and shortcoming of available sheet metal forming softwares. Based on the results of numerical analysis of front door outer panel forming. this paper evaluates the applicability of simulation results to the real die manufacturing for automotive body panels. Also it attempts to select an optimal die manufacturing process including design machining and tryout. Lastly it discusses the expected effects by adopt-ing the selected process in a real stamping die manufacturing facility.