• Transactions of Materials Processing
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• v.18 no.8
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• pp.596-600
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• 2009

Finite element simulation is an alternative method to practically find the forming limit diagram(FLD). In this paper, the novel fracture criterion is utilized to predict the FLD in conjunction with finite element analysis for sheet forming. The principal scheme of the fracture criterion in this paper is that growth of the micro voids leads up to fracture in the viewpoint of micro-mechanics. The numerical FLD is verified by results of the out-of plane stretching test using hemispherical punch. The verification is also conducted about two types of material. These results are in good accord with the experimental results. Especially, the proposed scheme is appropriate to predict FLDs for a restricted material with low ductility after the instability point or ultimate tensile strength.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.83-94
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• 1998

An analysis system for sheet metal forming has been developed to improve the design and tryout process by predicting the deformation behaviour more precisely. This analysis system consists of forming analysis, springback analysis and post processor modules. The more accurate prediction of stress history can be achived due to the improved contact algorithm. Successive simulation of several processes can be carried out conveniently without interrupt by the improved data management of the developed system. The error of data transfer between forming analysis and springback analysis is minimized using the proper shell element. Several benchmark test results and practical results are presented to show the effectiveness and reliability of this program.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.06b
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• pp.185-194
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• 1999

This paper suggests the new techmology to control metal flow in order to reduce the number of preforming and machining for the cold forged product with complex geometry. This technology can be summarized the complex forming, which consists of bulk forming and sheet forming, and multi-action forging, which be preformed double action dies. To analyze the process, finite element simulation has been performed. The proposed technology is applied to hub which is part of air conditioner clutch. According to the result of this study, the relative velocity of mandrel and punch is primary process variable.

• Transactions of Materials Processing
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• v.12 no.3
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• pp.236-243
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• 2003

Maintaining the required dimensional accuracy after springback becomes the main concern of sheet-forming die designers when formability is secured through beforehand tryouts. As a part to build guidelines for springback control in automobile frame forming, experiments are carried out to show the effects of process parameters, such as holding force, blank size, and lubrication, on corner angles of channels formed by U-bending or by square-cup drawing and trimming. The results predicted by a commercial FE package were compared with the experiment and the current limitations on springback evaluation were closely discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.322-325
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• 2005

In order to make a doubly-cowed sheet metal effectively, the sheet metal forming process has been developed by adopting the flexibility of the incremental forming process and the principle of bending deformation which causes slight deformation in thickness. The developed process is an unconstrained forming process without holder. The experimental equipment has been set up with the roll set which consists of two pairs of support rolls and one center roll. In order to analyze process parameters in the incremental roll forming process for the application to doubly curved ship hull plate, the orthogonal array is adopted. From the FEM results, among the process parameters, the distance between supporting rolls in pairs along the direction of one principal radius of curvature as well as the forming depth is shown to influence the generation of curvature in the same direction significantly. That is, the other distance between supporting rolls in pairs which are not located in the same direction of one principal radius of curvature, does not have an significant effect on the generation of the curvature in that direction. Also, the forming load and torque from the FEM simulation are acceptable to the system development of the incremental roll forming process for the forming of ship hull plate.

• Transactions of Materials Processing
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• v.20 no.7
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• pp.512-517
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• 2011

TRB(Tailor Rolled Blank) is an emerging manufacturing technology by which engineers are able to change blank thickness continuously within a sheet metal. TRB door inner panels with required larger thicknesses can be used to support localized high loads. In this study, the aluminum alloy 5J32 TRB sheet is used for a door inner panel application. The TRB material properties were varied by using three heat treatment conditions. In order to predict the failure of the aluminum TRB during simulation, the forming limit diagram, which is used in sheet metal forming analysis to determine the criterion for failure, was investigated. Full-field photogrammetric measurement of the TRB deformation was performed with an ARAMIS 3D system. A FE model of the door inner panel was created using Autoform software. The material properties obtained from the tensile tests were used in the numerical model to simulate the door inner of AA 5J32 for each heat treatment condition. After finite element analysis for the evaluation of formability, a prototype front door panel was manufactured using a hydraulic press.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.1
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• pp.132-141
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• 1998

A parallel version of sheet forming analysis program was developed. This version is compatible with any parallel computers which support MPI that is one of the most recent and popular message passing libraries. For this purpose, SERI-SFA, a vector version which runs on Cray Y-MP C90, a sequential vector computer, was used as a source code. For the sake of the effectiveness of the work, the parallelization was focused on the selected part after checking the rank of CPU consumed from the exemplary calculation on Cray Y-MP C90. The subroutines associated with contact algorithm was selected as targe parts. For this work, MPI was used as a message passing library. For the performance verification, an oil pan and an S-rail forming simulation were carried out. The performance check was carried out by the kernel and total CPU time along with theoretical performance using Amdahl's Law. The results showed some performance improvement within the limit of the selective paralellization.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.1171-1172
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• 2010

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.3
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• pp.78-85
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• 2008

Roll forming process is one of the most widely used processes in the world for forming metals. It can manufacture goods of the uniform cross section throughout the continuous processing. However, process analysis is very difficult because of the inherent complexity. Therefore, time is consuming and much money are needed for manufacturing goods. In order to overcome this difficulty, a new computational method based on the rigid-plastic finite element method is developed for the analysis of roll forming process. In this paper, the design of roll forming process and the simulation are performed to manufacture the upper member at under rail composed of three members. The cold rolled carbon steel sheet(SCP-1) is used in this simulation, and a flow stress equation is set up by conducting the tensile test. The upper member is designed using two types of design for a excellent design. Each types are simulated and compared with the strain distribution using SHAPE-RF software. In addition, the numerical magnitude of bow and camber which are the buckling phenomenon is estimated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.93-97
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• 1997

Since the modified membrane element has the same external appearance as the ordinary membrane element, it is not able to apply the thickness variation of sheet metal in the blank holder to the contact treatment and the equally distributed blank holding force should be inevitably imposed on sheet metal along the periphery regardless of the contact status. But sheet metal does not contact with the blank holder at the periphery, nor the blank holding force is distributed uniformly along the boundary. To impose the blank holding force properly, the scheme is improved so that the blank holding force at each node imposed on sheet metal is dependent on the calculated thickness derivation and a state of equilibrium with the total blank holding force. The validity of the improved scheme is demonstrated with the simulation of cylindrical and rectangular cup deep drawing.