• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.239-242
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• 2005

In the roll forming, a flat strip is progressively deformed by feeding it through a series of rotating rolls. There are various layouts for the tube toll-forming stages. The process sequences are as follows: leveling, roll-forming, welding, bead removing, seam annealing, cooling, sizing and cutting. Electric resistance welded(ERW) tubes have been widely used for the machinery parts, especially for hydroformed automotive parts. However conventional ERW tubes do not have a high formability because of hardening of welded portion by rapid cooling. Moreover the decrease in thickness of the welded portion during the grinding of the inner and outer bead may reduce the formability of the tube. In case of applying the tubular parts without grinding the bead, the flow of the fluid can be prevented due to the turbulent flow induced by the inner bead. In attempt to determine the optimal bead grinding amount in the roll forming process, in the present paper, the effects of the removal depth and width of the inner beads on the hydroformability are analyzed by the finite element simulation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.11
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• pp.1623-1630
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• 2010

In this study, effective forming methods for reducing the roll-over of a sector tooth, which is a main component of an automotive seat recliner, are proposed. Due to the large amount of roll-over, accurate contact between the inner gear of a sector tooth and the outer gear of a pawl tooth cannot be normally achieved; thus sensitivity and safety for the passengers decrease. To overcome the aforementioned drawback, we investigated the effect of flowcontrol forming methods involving local embossing die, coining punch, and VIC (Variable Inverse Clearance) on the roll-over depth by FE-analysis and an experiment. The results of a fine-blanking experiment for verifying the proposed methods showed that VIC type is decidedly superior from the aspects of reduction of roll-over and tool strength of the sector tooth.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.9
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• pp.1508-1516
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• 2003

In numerical analysis for hydroforming process, the stress calculation is effected by flow stress which is general obtained by stress-strain relationship from uni-axial tension test, so the result of the analysis, especially in tube hydroforming, has limitation of accuracy, tubes are made in roll-forming process and become work-hardened. Then roll forming process causes material properties between rolling direction and circumstantial direction of the tube to be different. So it is difficult to predict material behavior in the process condition of bi-axial stress state. In this study, the flow stress of the tube is determined by inverse engineering approach and bulge test that is widely used for formability test in the condition of bi-axial stress. And Hill's quadratic yield function and flow rule are used to consider the anisotropy of the tube in the roll forming process.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.4
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• pp.644-652
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• 2002

Increasing demands for Electric Resistance Welded pipes of high quality with thick wall require c lose investigations in edge deformation by slitting, strip deformation during break down farming, and difference of circumferential length. In order to obtain good quality of a welding zone, it is necessary to predict the edge shape of the initial strip. The modeling of the multi-pass thick tube roll forming process with rigid plastic finite element method ultra the edge shape prediction of an initial strip with 2nd-degree polynomial regression method are presented. Edge shapes of initial strip have been analyzed by the finite element method and designed by the regression method to satisfy the requirements in target fin pass. It is concluded that the proposed edge design method results in optimal edge shapes sat string the design requirements.

• Journal of the Society of Naval Architects of Korea
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• v.57 no.5
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• pp.297-304
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• 2020

In this study, the prediction method was reviewed to process a cylindrical plate forming using machine learning as a data-driven approach by roll bending equipment. The calculation of the forming variables was based on the analysis using the mechanical relationship between the material properties and the roll bending machine in the bending process. Then, by applying the finite element analysis method, the accuracy of the deformation prediction model was reviewed, and a large number data set was created to apply to machine learning using the finite element analysis model for deformation prediction. As a result of the application of the machine learning model, it was confirmed that the calculation is slightly higher than the linear regression method. Applicable results were confirmed through the machine learning method.

• Journal of Computational Design and Engineering
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• v.3 no.4
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• pp.337-348
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• 2016

An experimental approach is presented for the measurement of wear that is common in the threading of cold-forged steel. In this work, the first objective is to measure wear on various types of roll taps manufactured to tapping holes in microalloyed HR45 steel. Different geometries and levels of wear are tested and measured. Taking their geometry as the critical factor, the types of forming tap with the least wear and the best performance are identified. Abrasive wear was observed on the forming lobes. A higher number of lobes in the chamber zone and around the nominal diameter meant a more uniform load distribution and a more gradual forming process. A second objective is to identify the most accurate data-mining technique for the prediction of form-tap wear. Different data-mining techniques are tested to select the most accurate one: from standard versions such as Multilayer Perceptrons, Support Vector Machines and Regression Trees to the most recent ones such as Rotation Forest ensembles and Iterated Bagging ensembles. The best results were obtained with ensembles of Rotation Forest with unpruned Regression Trees as base regressors that reduced the RMS error of the best-tested baseline technique for the lower length output by 33%, and Additive Regression with unpruned M5P as base regressors that reduced the RMS errors of the linear fit for the upper and total lengths by 25% and 39%, respectively. However, the lower length was statistically more difficult to model in Additive Regression than in Rotation Forest. Rotation Forest with unpruned Regression Trees as base regressors therefore appeared to be the most suitable regressor for the modeling of this industrial problem.

• Journal of the Society of Naval Architects of Korea
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• v.46 no.6
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• pp.675-687
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• 2009

In general, the forming process of the curved hull plates consists of sub tasks, such as roll bending, line heating, and triangle heating. In order to complement the automated curved hull forming system, it is necessary to develop an algorithm to classify the curved hull plates of a ship into standard shapes with respect to the techniques of forming task, such as the roll bending, the line heating, and the triangle heating. In this paper, the curved hull plates are classified by four standard shapes and the combination of them, or saddle, convex, flat, cylindrical shape, and the combination of them, that are related to the forming tasks necessary to form the shapes. In preprocessing, the Gaussian curvature and the mean curvature at the mid-point of a mesh of modeling surface by Coon's patch are calculated. Then the nearest neighbor method to classify the input plate type is applied. Tests to verify the developed algorithm with sample plates of a real ship data have been performed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.101-105
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• 2005

Hemming process, composed of flanging, pre-hemming and main hemming, is the last one of a series of forming processes conducted on the automotive panels, having a great influence on the outward appearance of them. The hem quality can be quantitatively defined by the hemming defects including turn-down, warp and roll-in. However, it is difficult to evaluate and predict the hem quality through the experimental measurement or the numerical calculation since the size of defects is very small. This study is focused on how to simulate in the finite element analysis (FEA) the same conditions as in the experiment. The FEA result on turn-down, that was obtained from a finite element model including the spring element linked to the flanging pad, had a good correlation with the experimental data. It was found that the radius of curvature of the flange deeply affects the final hem quality and therefore high rigidity of forming tools and tight assembling tolerance are highly recommended. An over-stroke of the main hemming punch is also proposed to reduce the turn-down.

• Proceedings of the KWS Conference
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• 2003.11a
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• pp.18-20
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• 2003

Optimal processing and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from cool rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$ laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.12
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• pp.1563-1568
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• 2012

Printed electronics is a technology used for forming electronic circuits or devices, and it is used in the manufacture of many products such as RFID tags, solar cells, and flexible display panels with a much lower cost than in the case of semiconductor process technology. Web-guide-type printing such as roll-to-roll printing is a method used to produce printed electronic devices in a large volume. To commercialize such products, highly precise alignment between printed layers is required. In this study, a highly precise alignment system is proposed, and some experimental results are compared with those obtained using a laser surface vibrometer to illustrate the reliability of the proposed system. The robustness of the proposed system to web deformation is also considered experimentally.