• 한국정밀공학회지
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• 제17권9호
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• pp.62-69
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• 2000

Uneven clearances in the left and right sides of a press die cause deformation of the punch in precision shearing process. This deformation results from the compression stress and bending moment from shearing force in vertical direction and from the side force in horizontal direction acting to the punch, In this study the behavior of punch deformation is investigated in order to clarify the deformation state of the punch by using strain gauge deformation to shearing force side force bending moment radius of curvature and shear plane of the punch. Also we presented the calculation method of deformation size for the punch.

• 한국결정성장학회지
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• 제33권6호
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• pp.216-225
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• 2023

본 연구에서는 냉간 헤딩 공정에서 성형하중과 펀치 금형의 마모 감소를 통한 펀치 수명 증대를 위해 헤딩용 펀치 형상 최적설계를 수행하였다. 기존 생산에 사용되는 냉간 헤딩 펀치와 성형공정에 대한 유한요소해석 시뮬레이션을 통해 성형하중과 유동 특성 분석, 펀치금형에 집중되는 유효응력 및 마모량에 대하여 분석하였으며, 이를 통해 금형 마모와 밀접한 주요 설계인자를 확인하였다. 펀치금형의 최적설계 변수로서는 펀치 금형 포인트각(Point angle), 에지 반경값(Corner radius), 펀치소재재종(die material type), 마찰계수(friction coefficient) 등의 4가지 변수를 대상으로 4인자 3수준 인자 및 변수 수준을 설정하고, 성형해석 시뮬레이션과 다구찌법을 활용하여 설계인자별 영향도를 분석하여 최적의 최적설계 인자를 결정하였다. 본 연구를 통해 얻어진 최적설계변수를 적용하여 냉간 헤딩용 펀치 최적설계 시뮬레이션 결과, 각 펀치에 발생하는 최대유효응력은 최대 8.9 % 감소 효과를, 최대 펀치 마모 깊이는 37 % 감소 효과를, 성형하중은 평균 20% 수준 의 감소효과를 얻을 수 있었다. 현재, 소성 성형제품군이 적용되는 자동차, 건설 플랜트사에서 요구되는 고품질에 대응하면서도 적정 제조원가 절감을 위한 성형성 개선을 위한 성형공정개발 및 금형설계의 최적화가 지속적으로 필요하며, 향후 연구 결과를 현업에 적용하여 제품 성형성 개선 및 금형수명 증대 관리를 위한 기술자료로 활용하고자 한다.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2001년도 추계학술대회(한국공작기계학회)
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• pp.280-285
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• 2001

A good drawability of material itself is required. To improve the formability in deep drawing process. Besides that bending resistance should be reduced by increasing die round appropriately, drawing load should be minimized by improving the lubricant condition between die and material, and breaking load should be increased by selecting a pertinent punch round and by augmenting the friction resistance in Punch. In this study, a multi-stage deep drawing process is analyzed using ABAQUS, the effects of formability factors. Such as die shoulder radius, punch-die clearance and friction coefficient are investigated.

• Tribology and Lubricants
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• 제31권4호
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• pp.163-169
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• 2015

This paper describes a design method for the corner radius of a contacting body using the theoretical approach of contact mechanics. A complete contact, as in the case of a sharp-cornered punch, produces singular contact traction: whereas, in an incomplete contact, the singular contact traction disappears because of the rounded corners, and the contact edges are within the rounded regions. The design method aims to determine the conditions of the contact force as well as the material properties in an incomplete contact. The incomplete contact changes into the complete contact again when the contact edges exceed the rounded regions owing to either an increased contact force or the compliance of the materials. The contact length of a rounded punch is used as a parameter to derive the required conditions. As a result, a design formula is obtained, which provides a minimum allowable radius when the materials, normal contact force, and the length of a flat region of the punch are predetermined. This work consists of two parts: Part I includes a theoretical background, design method, and formula, and Part II describes the actual process with the investigation of design parameters.

• 소성∙가공
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• 제11권8호
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• pp.668-675
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• 2002

The circles deform into various shape during deformation, the major and minor axes of which indicate the direction of the major and minor principal strains. Likewise, the measured dimensions are used to determine the major and minor principal strain magnitudes. This circular grid technique of measuring strains can be used to diagnose the causes of necking and fracture in industrial practice and to investigate whether these defects were caused by material property variation, changes in lubrication, of incorrect press settings. In non-axisymmetric deep drawing, three modes of forming regimes are found: draw, stretch, plane strain. The stretch mode for non-axisymmetric deep drawing could be defined when the major and minor strains are positive. The draw mode could be defined when the major strain is positive and minor strain is negative, and plane strain mode could be defined when the major strain is positive and minor strain is zero. Through experiments the draw mode was shown on the wall and flange are one of a drawn cup, while the plane strain and the stretch mode were on the punch head and the punch corner area respectively, We observed that the punch load of elliptical deep drawing was decreased according to increase of die corner radius and the thickness deformation of minor side was more large than major side.

• 한국산학기술학회논문지
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• 제18권2호
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• pp.349-355
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• 2017

프레스금형(press dies)에 의한 굽힘가공(bending work) 이라는 것은 평평한 블랭크(blank)를 필요로 하는 각도(角度)로 굽히는 것이다. 굽힘가공을 하면 굽혀진부분(flange)과 굽혀지지 않은 부분(web)으로 구분되며, 굽힘라인(bending line) 부분에는 굽혀진 각도(bending angle)와 굽힘반지름(bending radius)이 내측과 외측으로 성형된다. 이때, 내측 굽힘반지름의 크기는 제품의 재질별로 최소치수가 제시 된다. 제시된 최소치수 보다 작게 굽히면 절단면 굽힘부위에 덧살이 발생 하거나 외측 굽힘반지름 부위에는 균열(crack)이 생긴다. 굽힘가공에서의 외측 굽힘반지름은 자연적으로 생긴다. 그래서 외측 굽힘반지름 치수를 굽힘펀치와 다이블록으로 조정하면서 필요한 치수로 굽힐수 없다. 굽힘가공에는 V-굽힘, U-굽힘, Z-굽힘, O-굽힘, P-굽힘, 에지굽힘(edge bending), 트위스트굽힘(twist bending), 크림핑(crimping) 등이 있다.이 중에서 Z-굽힘은 굽힘라인이 2개로써 블랭크의 상면(上面)과 하면(下面)에 설정하여 상향(上向)굽힘이나 하향(下向)굽힘으로 작동되는 금형을 사용한다. Z-굽힘을 크랭크굽힘(crank bending) 이라고도 한다. 이런 구조의 금형으로 Z-굽힘가공을 하면 내측반지름은 표준치수로 굽혀진다. 표준치수라는 것은 굽힘가공에서 굽힐 수 있는 최소 굽힘반지름 치수로서 굽힘펀치의 각(角)반지름(Rp)를 뜻한다. 그런데 산업현장에서는 외측 굽힘반지름 치수를 굽힘펀치와 다이블록으로 굽힐수 없는 미세한 샤프에지(sharp edge) 형상인 매우 작은 치수(R=0.2mm)를 필요로하고 있는 바, 본 논문에서는 외측 굽힘반지름 치수를 0.2mm 이하로 굽힐수 있는 Z-굽힘가공 공법을 개발 하고자 하였다.

• 소성∙가공
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• 제16권2호
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• pp.120-125
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• 2007

Magnesium alloy has low formability at room temperature and therefore, in many cases, forming at elevated temperatures is necessary to obtain the required material flow without failure. Tn the present study, square cup deep drawing tests using the magnesium alloy AE31 sheet were experimentally conducted using the porches and dies with different edge radius to evaluate the formability sensitivity to the die design variables. The experimental results showed that the fracture position over the cup wall moved from the punch nose to the flange as the die temperature increased, and that the drawing depth change was more affected by the punch radius than the die radius.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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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.

• 소성∙가공
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• 제13권5호
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• pp.461-465
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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 comer 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.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1997년도 추계학술대회논문집
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• pp.158-163
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• 1997

In this paper the tool geometry of the PSS test were optimized in order to assure the reliability of the test. Considering many factors for optimization of the tool geometry, computer-simulation technique using three-dimensional finite element method(FEM) was used. Three design variables -the punch length, punch crown and punch corner radius- are chosen to be optimized according to the Taguchi's experiment technique with the L9 orthogonal array. The optimum condition to ensure the plane strain mode over the overall area of the specimen was clarified. Moreover the simulation results are confirmed by experiment.