• 소성∙가공
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• 제13권6호
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• pp.497-502
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• 2004

The shape of cold rolled steel sheets is defined as the degree of flatness, and the flatter, the better. Because undesirable strip shapes of cold rolled steel sheets can affect not only visible problem but also automatic working process in customer's lines, the requirement of the customers is more and more stringent. So we usually used the tension leveler to make high quality of strip flatness. For the improvement of the quality of strip flatness, this report developed three- dimensional FEM (Finite Element Method) simulation model, and analysis about the strain and stress distribution of strip in the tension leveling process. The numerical study can be summarized as follows. (1) If we pass the edge wave material (steepness: $1.0\%$) that the stress-difference between the strip center and the edge is 5.2kgf through tension leveler. the stress-difference is decreased 0.45kgf and the steepness is improved to $0.29\%$. (2) If the Intermesh is increased from 6mm to 7mm, the steepness is improved from $0.294\%$ to $0.268\%$. (3) If the initial steepness is decreased form $1.0\%$ to $0.75\%$, the final steepness is improved from $0.294\%$ to $0.263\%$. We know that more increased intermesh and lower initial steepness make the final steepness improved.

• 소성∙가공
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• 제14권6호
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• pp.527-532
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• 2005

Among the failure modes which can occur in tube hydroforming such as wrinkling, bursting or buckling, the bursting by local instability under excessive tensile stresses is irrecoverable phenomenon. Thus, the accurate prediction of bursting condition plays an important role in producing the successfully hydroformed part without any defects. As the classical forming limit criteria, strain-based forming limit diagram (FLD) has widely used to predict the failure in sheet metal forming. However, it is known that the FLD is extremely dependant on strain path throughout the forming process. Furthermore, The application of FLD to hydroforming process, where strain path is no longer linear throughout forming process, may lead to misunderstanding for fracture initiation. In this work, stress-based forming limit diagram (FLSD), which is strain path-independent and more general, was applied to prediction of forming limit in tube hydroforming. Combined with the analytical FLSD determined from plastic instability theory, finite element analyses were carried out to find out the state of stresses during hydroforming operation, and then FLSD is utilized as forming limit criterion. In addition, the approach is verified by a series of bulge tests in view of bursting pressure and shows a good agreement. Consequently, it is shown that the approach proposed in this paper will provide a feasible method to satisfy the increasing practical demands for judging the forming severity in hydroforming processes.

• 소성∙가공
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• 제19권2호
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• pp.120-126
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• 2010

The line array roll set(LARS) process, as one of many kinds of incremental forming processes, is a continuous process in which a flat metal plate is formed into a singly or doubly curved plate through successive passes of forming rolls. It was found that the curvature level of the formed plates in the previous study was well over the curvature required in shipyards. This fact shows that the LARS method has good potential for shipbuilding applications. The major purpose of the present study is to estimate experimentally the general applicability of the line array roll set process for the manufacture of ship hull plates. In this study, the target shapes are selected through investigation of the shape classification of ship hull plates that comprise a certain vessel. Forming processes for twisted shapes are analyzed with the finite element method(FEM) and the results of experimental work are presented. On the basis of the experimental and numerical results, the LARS process is applied to the production of real outer hull plates of a small patrol ship.

• 소성∙가공
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• 제19권2호
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• pp.79-87
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• 2010

The Pipe bending process using high frequency local induction heating is an advanced technique to bend pipes with a small bending radius and a large diameter. Even though the pipe bending process is a quite widespread engineering practice, it depends heavily upon trial and error method by field engineers with several years of experience. So it is necessary to develop an integrated methodology for optimum design of the pipe bending process. During hot pipe bending using induction heating, outward wall thickness of a pipe is thinned due to tensile stress and the reduction of wall thickness is not allowed to exceed 12.5%. Taguchi method and dynamic reverse moment is proposed to maintain a reduction ratio of thickness within 12.5%, when D/t ratio is high. An application of the proposed approach was compared with those of the finite element analysis and has good in agreements.

• 소성∙가공
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• 제24권3호
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• pp.199-204
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• 2015

Electromagnetic Forming is a high speed forming technology which uses electromagnetic (Lorentz’s) forces to shape sheet metal parts. In the current study the effect of the tool-sheet interaction during electromagnetic forming on formability enhancement is investigated using FEM. The decrease in void volume fraction by having the sheet contact with die helps to improve formability. The main purpose of the current study was to predict improvement of formed sheets whether the sheet contacts or does not contact the die under experimental conditions and 3-D finite element analysis. The results show that fractures caused by the voids in the forming sheet appear only in some specific cases and the bulge height of the conical shape was shorter than the height with a free bulge. For the same height conditions, however, the formability was improved for the conical-shaped die when there is sheet contact with the die.

• 소성∙가공
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• 제24권3호
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• pp.187-193
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• 2015

The objective of the current study is to determine cross-sectional profile of intermediate dies in order to improve the plastic strain homogeneity which directly affects not only the dimensional accuracy but also the mechanical properties of final product by redesigning the intermediate dies using the conventional electric field analysis (EFA) method. Initially, the multi-pass shape wire drawing was designed by using the equivalent potential lines from EFA. The area reduction ratio was calculated from the number of passes in multi-pass shape wire drawing but constrained by the capacity of the drawing machine and the drawing force. In order to compensate for a concentration of strain in a region of the cross section of the wire, the process for multi pass wire drawing from initial round material to an intermediate die was redesigned again using the electric field analysis. Both drawing process designs were simulated by the finite element method in which the strain distribution and standard deviation plastic strain of the cross section of drawn wires were examined.

• 소성∙가공
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• 제17권6호
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• pp.393-400
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• 2008

Springback is one of the most difficult phenomena to analyze and control in sheet forming. Most of traditional springback control methods rely on experiences of skilled workers in industrial fields. This study focuses on prediction and generation of optimum reconfigurable die surfaces to control shape errors originated by springback. For this purpose, a deformation transfer function(DTF) was combined with finite element analysis of the springback in the 2D sheet forming model of elastic-perfectly plastic materials under the condition without blank holder. The results showed shape errors within 1% of the objective shape, which were comparable with analytically predicted errors. In addition to this theoretical analysis, DTF method was also applied to 2D and 3D sheet forming experiments. The experimental results showed ${\pm}0.5$ mm and ${\pm}1.0$ mm shape error distribution respectively, demonstrating that reconfigurable die surfaces were predicted well by the DTF method. Irrespective of material properties and sheet thickness, the DTF method was applicable not only to FEM simulation but also to 2D and 3D elasto-reconfigurable die forming. Consequently, this study shows that springback can be controlled effectively in the elasto-RDF system by using the DTF method.

• 소성∙가공
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• 제17권6호
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• pp.420-428
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• 2008

The effect of loading path changes on the strain and mechanical properties of a commercial pure aluminum was studied using flat rolling and groove rolling. Material during flat rolling undergoes a continuous monotonic compressive loading, while one during groove rolling experiences a series of cross compressive loading. Four-pass flat rolling and groove rolling experiment are designed such that the aluminum undergoes the same amount of the strain at each pass. The rolling experiment was performed at room temperatures. Specimens for tensile test are fabricated from the plate and bar rolled. In addition, the strain distribution for the plate and bar cold rolled specimens is also calculated by finite element method. The results reveal that differences of loading path attributed by monotonic loading(flat rolling) and cross loading(groove rolling) significantly influence the mechanical properties such as yield stress, ultimate tensile stress, strain hardening and elongation. It is clear that the different loading path can give raise to change the deformation history, although it is deformed with same amount of strain for same material.

• 소성∙가공
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• 제21권1호
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• pp.58-66
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• 2012

The work roll surface temperature rises and falls repetitively during hot slab rolling because the work roll surface is cooled continuously by water. This study focused on Std. No. 7 to determine a cooling method which significantly reduces the tangential tensile stresses on the work roll surface of the hot slab mill at Hyundai Steel Co. in Korea. A series of finite element analyses were performed to compute the temperature distribution and the tensile stresses in the circumferential direction of the work roll. The virtual slab model was used to reduce the run time considerably by assigning a high temperature to the virtual slab. Except for the heat generated by plastic deformation, this is equivalent to the hot rolling condition that a high temperature slab (material) would experience when in contact with the work rolls. Results showed that when the virtual slab model was coupled with FE analysis, the run time was found to be reduced from 2000 hours to 70 hours. When the work roll surface cooled with a certain on-off patter of water spray, the magnitude of the tangential stresses on the work rolls were decreased by 54.1%, in comparison with those cooled by continuous water spraying. Savings of up to 83.3% in water usage are possible if the proposed water cooling method is adopted.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.439-443
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• 2008

We investigate the mechanical behavior of a pre-heat treated steel of ESW95, which is being used for automotive parts including tie-rods to save manufacturing cost and enhance product quality. SCM435 is also investigated to reveal the characteristics of the pre-heat treated steel tested. AFDEX/MAT is used to extract the true stress-strain curve over the large strain with higher accuracy. It has been found that ESW95 has very week strain-hardening behavior which can be negligible compared with SCM435 and that the initial yield strength is quite high and the toughness of ESW95 reaches nearly 75% of SCM435. ESW95 is characterized by the weak strain-hardening behavior and high yield strength that can be lead to minimization of post-processing including heat treatment and straightening. ESW95 and SCM435 are also compared by applying them to ball-stud forging by computer simulation. It is expected that a great deal of change may take place in production as well as in service if the pre-heated steels are adopted.