• Journal of the Korean Society for Precision Engineering
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• v.18 no.8
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• pp.182-192
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• 2001

During the deep drawing process an initially flat blank is clamped between the die and the blank holder after which the punch moves down to deform the clamped blank into the desired shape. In general, sheet metal forming may involve stretching, drawing, bending or various combinations of those basic modes of deformation. The deformation problems of sheet metal working involve non-linearity in geometry and material. In this work, The punch load and thickness strain of electro-galvanized sheet steel (SECD) for elliptical deep drawing are examined under the various process conditions including, punch shape radius, die shape radius. The changes of punch load and thickness strain distribution of the deformed elliptical cup are affected by the size of each die shape radius.

• Design & Manufacturing
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• v.16 no.3
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• pp.28-33
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• 2022

The recent increasing application rate of advanced high-strength steel(AHSS) for automotive parts makes it difficult to ensure the durability of forming tools. Significant load and friction generated during the piercing process of AHSS increase the wear rate and the damage degree to dies. These harsh process conditions also yield product failures, such as dimensional inconsistency of pierced holes and insufficient quality of hole's sheared edge. This study analyzed the effect of punch wear on the sheared surface of pierced parts and the forming load during the piercing process. Wear-shaped punches showed approximately 20% higher piercing load than normal-shaped punches, and the rollover ratio of the sheared surface also increased. It is considered that the dull edge of wear-shaped punches does not penetrate directly into the material but shears after tensioning it in a piercing direction. In addition, wear-shaped punches experienced compressive load even after completing the piercing process during the down-stroke and tensile load during the up-stroke. This load variation is related to the smaller diameter piercing holes produced by wear-shaped punches compared to normal-shaped punches. Thus, we demonstrated the predictability of the wear level of dies through a comparative analysis of the piercing load pattern.

• Transactions of Materials Processing
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• v.14 no.1 s.73
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• pp.57-64
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• 2005

This study deals with the cold forging process design for shaft in the main part of automobile motors with rectangular deep groove. In forging process, the accuracy and die lift is very important because it have influence on reduction of the production cost and the increase of the production rate. Therefore, it is necessary to develop the manufacturing process of shaft by cold forging., process variables are the cropped face angle of billet and the eccentric load of punch. The former is derived from cropping test, the latter is occurred by clearance between container and preform. Also, grooved preform select the process variable for decrease in punch deflection. We investigate that a deflection of punch and a deformation of preform to every process variables. Through this investigation, we suggest the optimal preform and process design, expect to be improved the tool life in forging process.

• Transactions of Materials Processing
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• v.21 no.2
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• pp.89-95
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• 2012

To examine the deformation characteristics of round aluminum pipe under biaxial compression, a horizontal biaxial compression die was fabricated. The change of material properties, punch load and deformation behavior were monitored in experiments using various compressive deformation rates in the range of 1mm/min.~400mm/min. The tensile and compressive strains were estimated from Vickers microhardness results. The punch load and deformation characteristic of the round aluminum pipes were found to change greatly at a deformation rate of about 200mm/min. The punch load decreased with increasing compressive deformation rate. Results of numerical simulation using Deform-2D were in good agreement with experimental results, and the measured hardness variation with the strain variation was predicted well by the simulation.

• Transactions of Materials Processing
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• v.22 no.2
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• pp.67-73
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• 2013

The deformation characteristics and microstructure changes in a round copper pipe under biaxial compression was studied using a horizontal compression die. The change of material properties, punch load and deformation behavior were monitored using various compressive deformation rates in the range of 0.5mm/min.~450mm/min. The strains, either tensile or compressive, were estimated from Vickers microhardness test results. The punch load and deformation characteristics of the round copper pipes were found to change greatly at a deformation rate of about 200mm/min. The punch load decreased with increasing compressive deformation rate. The results of numerical simulations agreed well with what was expected from the final microstructure and the hardness profile estimated from the final deformation strains.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.7 s.178
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• pp.1753-1762
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• 2000

An inverse method is presented to obtain material's flow properties by using small punch test. This procedure employs, as the objective function of inverse analysis, the balance of measured load-di splacement response and calculated one during deformation. In order to guarantee convergence to global minimum, simulated annealing method was adopted to optimize the current objective function. In addition, artificial neural network was used to predict the load-displacement response under given material parameters which is the most time consuming and limits applications of global optimization methods to these kinds of problems. By implementing the simulated annealing for optimization along with calculating load-displacement curve by neural network, material parameters were identified irrespective of initial values within very short time for simulated test data. We also tested the present method for error-containing experimental data and showed that the flow properties of material were well predicted.

• Proceedings of the KSME Conference
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• 2000.11a
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• pp.193-198
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• 2000

The small punch test have been developed to evaluate the material strength of the power plant components. This small punch test specimen is very small than the conventional strength test specimens. Korea Electric Power Research Institute (KEPRI) have been applying this test to assess accurately the life of thermal power plant and enhancing the reliability. The small punch test for gas turbine blades is under development. It's possible to compare the relative strength among the same materials having different operation histories. In this paper, the strength reductions of gas turbine materials are investigated by the small punch tests. All materials shows the almost same strength and deformation with the allowable deviation. At the same test temperature, the damaged material has the maximum load value. The strength reduction is not shown in this small punch test results.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.9
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• pp.517-524
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• 2019

The overdrive hub clutch is attached to a 6-speed automatic transmission to reduce fuel consumption by using the additional power of the engine. This paper proposes a means to minimize the load and roll-over ratio on the punch during the piercing process for the overdrive hub clutch product. Die clearance, shear angle, and friction coefficient, which can affect the load and roll-over ratio of the punch during processing, were set as the design variables. Sensitivity analysis was also conducted to determine the influence of each design variable on the punch load and roll-over ratio. As a result, shear angle, friction coefficient and die clearance were found to be sensitive to load and roll-over ratio. The punch load and roll-over ratio were set as the objective function and the equation of each design variable and objective function was derives using the Response Surface Method. Finally, the optimal value of the design variables was derived using the Response Surface Method. Application of this model to finite element analysis resulted in 22.14% improvement in the roll-over ratio of the punch load and material.

• Structural Engineering and Mechanics
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• v.78 no.2
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• pp.135-143
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• 2021

In this study, continuous contact problem in the functionally graded (FG) layer loaded with a FG flat punch resting on the elastic semi-infinite plane was analyzed by the finite element method (FEM). It was assumed that the shear modulus and density of the layer and punch varied according to exponentially throughout their depth. FG layer's weight was included to the problem and additionally all surfaces were considered as frictionless. Analysis of FG materials was performed with a special macro which was added to the ANSYS program. Firstly, the shear modulus of the punch was considered to be very rigid and the results of initial separation load (λcr) and distance (xcr) were compared with the analytical solution. Afterwards, results obtained from the contact analysis made according to the inhomogeneity parameters (β, γ) between FG punch-FG layer which had been unprecedented in the literature were discussed. As a result, FG punch's stress values at the punch edges where stress accumulations occurred were found to be smaller than the rigid punch. The security of the structure, longer life of the material and ease of production are directly related to the reduction of the stress values. The results obtained in this study are important in this respect. Also this work is the first study that investigates the effect of FG punch on the FG layer.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.182-185
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• 2004

Based on the experimental observation, the mathematical friction model, which is an essential information for analyzing the forming process of sheet metal, is developed considering lubricant viscosity, surface roughness and hardness, punch corner radius, and punch speed. By comparing the punch load found by FEM with a proposed friction model with experimental measurement when the coated and uncoated steel sheets are formed in 2-D geometry in dry and lubricant conditions, the validity and accuracy of the developed friction model are demonstrated.