• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.310-313
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• 2007

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. In this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal roll flower model and proper roll-pass sequence can be suggested by analyzing courcenter strain and longitudinal strain according to the roll-pass with FEM simulation. And also effects of the process parameters on the final shape formed by roll forming defects a evaluated.

• Proceedings of the KWS Conference
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• 2005.06a
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• pp.370-376
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• 2005

Magnesium alloys are becoming important material for light weight car body, due to their low specific density but high specific strength. However they have a poor weldability, caused high oxidization tendency and low vapor temperature. In this study, the welding performance of magnesium alloys was investigated for automobile application. The materials were rolled magnesium alloy sheet contains Al and Zn such as AZ3l , AZ6l and AZ9l. Three types of welding process were studied, that were GTAW, Laser beam welding and FSW. To evaluate the weldability, we examined the appearance of welding bead. Also we checked bead shape and internal defects such as crack and porosity on cross section of welding bead. The mechanical property was measured for welded specimen by tensile test. For determination of the strength change by welding process, the hardness profile across the welding center was measured. For the results, the tensile properties of welded specimen were decreased obviously on all welding process. For the fusion welding process such as GTAW and laser beam welding, the surface of the welding bead was covered with oxidized magnesium dust but it was removed by simple cleaning work as wipe-out with tissue. Also under cut, that caused vaporization of base metal was occurred. for the friction stir welding, there was no oxidation, under-cut or internal defects. However it had poor weld performance, the reason was cleavage fracture occurred at plastic deformation zone. For welding of magnesium alloy, the laser beam welding process was recommended.

• Journal of Welding and Joining
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• v.29 no.2
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• pp.80-87
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• 2011

In this study, the friction stir spot welding (FSSW) of Mg alloy sheets has been tried using an apparatus devised with a CNC milling machine to give the precise control of joining condition including tool speed. The probe tool used is made of hard metal and composed of cylindrical shoulder and pin parts. The variation of morphologies formed after the friction stir spot welding depending on the plunge speed of the tool were investigated at each rpm of tool. The history of the temperature distribution and the vertical load induced during the spot welding with friction time were measured by using an Infrared Thermal Imager (THERMA CAMTM SC2000) and a loadcell located below the specimen fixture, respectively. Tensile-shear tests were also performed to evaluate the fracture load of welded specimens. In order to characterize the friction stir spot welding of Mg alloy sheets, the variation of the fracture load was discussed on micrographic observations, temperature distribution during the FSSW according to the plunge speeds of tool.

• Transactions of Materials Processing
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• v.9 no.6
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• pp.670-680
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• 2000

The purpose of this study is to provide the database of forming limit diagram applicable to the warm forming of oil pan. The test materials are SCP1 and SCP3C with the thickness of 1.4mm which is used for the oil pan of automobile. The testing temperature is 5$^{\circ}C$~15$0^{\circ}C$ which is In the range of practical usage. The results are the forming limit diagram limiting dome height and the maximum punch load at each temperature such as 5$^{\circ}C$, $25^{\circ}C$, 6$0^{\circ}C$, 9$0^{\circ}C$, 12$0^{\circ}C$ and 15$0^{\circ}C$. From these results, we can see that the forming limit curves are translated depending upon the temperature and that FLC at low temperature is higher than at high temperature. Both of limiting dome height and maximum punch load also decrease as the temperature increases. Present results can be useful for die trial and forming analysis as a tool of evaluating the forming severity for the sheet metal forming processes at the warm working condition by comparing the practical strains with FLC.

• Journal of Ocean Engineering and Technology
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• v.15 no.2
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• pp.72-78
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• 2001

The bead is used to provide properly restraining force in the sheet metal forming process. This bead process includes bending and geometrical non-linearity, and affects the state of binderwrap. Therefore, the analysis of bead process is very important to obtain the desired formability. In this paper, the research about the influence of the punch stroke of bead on the draw-bead process was conducted. Results from the analysis will give useful information to the effective tool design of blank forming process. To analyze the bead process, and elasto-plastic finite element formulation is constructed from the equilibrium equation and the considered boundary conditions involved a proper contact condition. The static-explicit finite element method as a numerical method for the analysis was applied to the analysis program code. It was found that this method could solve too much computation time and convergence problem owing to high non-linearity of bead forming process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.82-87
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• 2012

The purpose of this study is to produce a side impact beam with high tensile steel using a roll forming process. The door side impact beam plays an important roll in a car because it protects passengers from external crash. The roll forming process is a continuous bending process wherein a long metal sheet is bended as it continuously passes several rolls. The characteristic of this study is that an impact beam is produced by a continuous process using a ultra high strength steel without a hardening heat treatment. A model was determined by analysing plasticity of a cross section shape considering high strength. Design parameters of the impact beam was determined by crash-analysing the model. Workpiece products were manufactured by designing dies for roll forming and setting them up in a following process line. Results of a bending test and a FEM analysis was considered and reviewed.

• Structural Engineering and Mechanics
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• v.31 no.4
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• pp.439-451
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• 2009

The paper deals with the problem related to the modelling of riveted assemblies for crashworthiness analysis of full-scale complete aircraft structures. Comparisons between experiments and standard FE computations on high-energy accidental situations onto aluminium riveted panels show that macroscopic plastic strains are not sufficiently localised in the FE shells connected to rivet elements. The main reason is related to the structural embrittlement caused by holes, which are currently not modelled. Consequently, standard displacement FE models do not succeed in initialising and propagating the rupture in sheet metal plates and along rivet rows as observed in the experiments. However, the literature survey show that it is possible to formulate super-elements featuring defects that both give accurate singular strain fields and are compatible with standard displacement finite elements. These super-elements can be related to the displacement model of the hybrid-Trefftz principle of the finite element method, which is a kind of domain decomposition method. A feature of hybrid-Trefftz finite elements is that they are mainly used for elastic computations. It is thus proposed to investigate the possibility of formulating a hybrid displacement finite element, including the effects of a hole, dedicated to crashworthiness analysis of full-scale aeronautic structures.

• Journal of the Korean Solar Energy Society
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• v.23 no.3
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• pp.15-22
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• 2003

This study deals with the collection of solar energy and its storage in evacuated tubular collector systems for different types of header design, flow passage and heat transfer devices. In order to elicit the most efficient combination of header design, flow passage, heat transfer hardware and operating conditions, a series of tests were done for the four different types of solar collectors utilizing vacuum tubes. The systems studied here either has the evacuated collector tubes with a metal cap on one end or the all-glass evacuated solar collector tubes These evacuated tubular collectors are known to be more efficient than the flat-plate ones in both direct and diffuse solar radiation. Test results show that the system comprised of the all-glass evacuated tubes with U-shaped copper pipes inside outperforms the other configurations. Especially, a rolled copper sheet tightly placed along the inner surface of each inner tube enhances heat transfer between the heated collector surface and the water contained in the U-shaped copper pipe.

• Proceedings of the Membrane Society of Korea Conference
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• 1999.07a
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• pp.43-47
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• 1999

Pd-ceramic composite membranes and catalytic membrane reactors(CMR) have been studied for hydrogen purification and recovery in th fusion reactor fuel cycle. The development of techniques for coating microporous ceramic tubes with Pd and Pd/Ag layers is described: composite membranes have been produced by electroless deposition (Pd/Ag film of 10-20${\mu}{\textrm}{m}$) and rolling of thin metal sheet (Pd and Pd/ Ag membranes of 50-70 ${\mu}{\textrm}{m}$). Experimental results on electroless membranes showed that the metallic film presented some defects and the membranes had not complete hydrogen selectivity . Then the catalytic membrane reactors with electroless membranes can be applied for some industrial processes that do not require a complete separation of the hydrogen (i.e. in the dehydrogenation of hydrocarbons). The rolled thin Pd/Ag membranes separated the hydrogen from the other gas with a complete selectivity and exhibited a slightly larger (about a factor 1.7) mass transfer resistance with respect to the electroless membranes. Experimental tests confirmed the good performances in terms of durability.

• Design & Manufacturing
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• v.10 no.2
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• pp.44-49
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• 2016

The roll forming produces mass products using the continuous production process. Also we need the process that continuous long material or goods cutting into a desired length. Our study uses 3-D driving cutter and roll forming material as SPCC to investigate this. When we cut the material using the process of roll forming, the shear resistance is raised at the cutting punch's edge. The result is remained the trouble about burr and progressive deformation on the material. This study shows the method minimizing the above trouble. The material of punch was considering heat generated on the continuous production process. So we used the type of STD 61 for the material of punch and had the vacuum heat treatment for the surface hardness of HRC 53. The structure of the mold is designed with forming a double cam die at the upper punch and the both sides of central core. We conducted the experiment three times. In the result when had to make V-groove within the angle between 105 and 110 on the punch front end, we could get the minimum shear resistance on the punch front end. Also with the same condition we minimizes the material jams in the continuous production process.