• 열처리공학회지
• /
• 제18권2호
• /
• pp.105-111
• /
• 2005

In sheet metal forming, drawbeads are often used to control uneven material flow, which may cause defects such as wrinkles, fractures, surface distortion and springback. Appropriate setting and adjusting of the drawbead force is one of the most important parameters in sheet forming process control. Therefore in this study, drawbead test was performed at various bead surface treatment conditions to clarify the frictional characteristics between sheet and drawbead. Furthermore, the differences in drawing force between circular and rectangular shape beads have also been measured to estimate the effectiveness of bead shape on the material flow control. The results show that drawing and friction characteristic were strongly influenced by surface treatments of bead and bead shapes.

• Journal of Welding and Joining
• /
• 제34권3호
• /
• pp.6-11
• /
• 2016

Joining Al/Fe dissimilar metals is becoming a subject of special interest in the assembly of automotive parts as a trade-off between the weight lightening and the cost reduction. Although various studies have been introduced to join Al alloy with the steel sheet by fusion welding, weak joint strength and galvanic corrosion still remained as problems to be solved. As a solid state welding, friction stir welding has been preferred to fusion welding processes in the dissimilar metal joints. This study investigated friction stir spot welding (FSSW) of Al alloy to the thin steel sheet with a thickness of 0.65 mm. The conventional FSSW is a stationary spot welding process but new approach adopted an additional circumferential movement in company with high speed tool rotation. A full factorial experimental design was implemented, and the main and interaction effects of parameters were analysed on the failure load in the tensile shear test. The direction and radius of rotation were statistically significant parameters and these two parameters affected the joint width and the shape of the hook.

• 소성∙가공
• /
• 제24권6호
• /
• pp.405-410
• /
• 2015

Sheet-forming of Mg alloys is conducted at elevated temperatures (250℃) due to the low formability at room temperature. The high-temperature process often gives rise to surface damage on the alloy (i.e. galling.) In the current study, the frictional characteristics of DLC coating slid against an AZ31 Mg alloy at various temperatures were investigated. The coating has been used widely for low-friction processes. Dry-sliding friction and galling characteristics of an AZ31 Mg alloy (disk), which slid against uncoated and a DLC-coated STD-61 steel (pin), were investigated using a reciprocating-sliding tribometer at room temperature and 250℃. To represent the real sliding phenomena during a sheet metal forming process, single-stroke tests were used (10mm stroke length) rather than a reciprocating long sliding-distance test. The DLC coating suppressed adhesion between the alloy and the tool steel at room temperature, and exhibited a low friction coefficient. However, during sliding at 250℃, severe adhesion occurred between the two surfaces, which resulted in a high friction coefficient and galling.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2006년도 추계학술대회 논문집
• /
• pp.397-398
• /
• 2006

• Tribology and Lubricants
• /
• 제28권5호
• /
• pp.240-245
• /
• 2012

In this study, we developed a new carrier finger to prevent scratches in a sheet metal forming line. The developed carrier finger was designed to have a streamlined shape with a larger radius of curvature at the edges, as well as a smaller contact area. To evaluate the scratch alleviation effect, a sliding contact analysis and scratch test using the pin on a plate wear tester were conducted for both the old and new carrier fingers. The results show that, for both transverse and longitudinal movements of the strip, the newly designed carrier finger reduces both the friction and scratch depth by its streamlined shape, which decreases the pressure spike at the edge.

• 소성∙가공
• /
• 제11권5호
• /
• pp.394-404
• /
• 2002

The drawbead model for a three-dimensional a finite element analysis of sheet metal forming processes is developed. The mathematical models of the basic drawbeads like circular drawbead, stepped drawbead, and squared drawbaed are first derived using the bending theory, belt-pulley equation, and Coulomb friction law. Next, the experiments for finding the drawing characteristics of the drawbead are performed. Based on mathematical models and drawing test results, expert models of basic drawbeads are then developed employing a linear multiple regression method. For the expert models of combined drawbeads such as the double circular drawbead, double stepped drawbead, circular-and-stepped drawbead, etc., those of the basic drawbeads are summed. Finally, in order to verify the expert models developed, the drawing characteristics calculated by the expert models of the double circular drawbead and circular-and-stepped drawbead are compared with those obtained from the experiments. The predictions by expert models agree well with the measurements by experiments.

• International Journal of Ocean System Engineering
• /
• 제3권3호
• /
• pp.147-151
• /
• 2013

This study was to correctly estimate the friction and wear behavior of carbon fiber and PEEK sheet composites, and the validity of using them as alternatives to the metal-based materials used for artificial hip joints. Moreover, this work evaluated the friction coefficient according to the fiber ply orientation, along with the fractured surfaces of the carbon/PEEK composites. The unidirectional composites had higher friction coefficients than those multidirectional composites. This was caused by the debonding between the carbon fiber and the PEEK sheet, which was proportional to the contact area between the sliding surface and the carbon fiber. The friction test results showed that there was no significant differences in relation to the fiber ply orientation. However, in a case where the speed was 2.5 m/s, the friction coefficient was relatively large for configuration I. The friction surface of the specimen was analyzed using an electron microscope. In all cases, the debonding of the fiber and PEEK could be confirmed.

• 한국정밀공학회지
• /
• 제24권3호
• /
• pp.91-99
• /
• 2007

Fractures of galvannealed coating layer during actual press forming in automotive applications were observed by scanning electron microscopy in order to understand fracture mechanism. Fracture behaviors of galvannealed coating layer in extra deep drawing quality steels and high strength steels have been studied by performing the tests describing the representative plastic deformation in sheet metal forming such as uni-axial tensile test, compression test, bi-axial test and plane strain test. Growth and direction of cracks were deeply related to the plastic deformation modes and history. The material properties of galvannealed coating layer were investigated by nano-indentation test equipped with Berkovich diamond indentor for the specimens. Hardness and elastic modulus of the coating layer were higher than bared steels and that was the reason for crack of coating layer. Flat friction test and drawbead friction test were performed to observe the effect of the surface morphology on the frictional characteristics. The micro-plasto hydrodynamic lubrication were appeared and played an important role in reducing the coefficient of friction.

• 소성∙가공
• /
• 제9권4호
• /
• pp.379-388
• /
• 2000

This study aims to examine the influence of experimental and numerical factors on the results of the test and finite element simulation to evaluate the formability of sheet metals. The stretch-forming test with a hemispherical punch is carried out to obtain the limiting dome height (LDH) and forming limit diagram (FLD) for several kinds of aluminium and steel sheet. The results of the LDH and FLD tests are analysed to find any correlation with the uniaxial tensile properties. It proves that the size of the prescribed grid has great influence on the measured value of strain. The finite element analysis of the punch stretching process is also carried out and the result is compared with the experimental data. The influence of the numerical parameters such as friction coefficient, element size and anisotropy model on the simulation results tms out to be very considerable.

• 대한기계학회논문집A
• /
• 제30권11호
• /
• pp.1425-1432
• /
• 2006

Coating layers on a coated sheet steel frequently affect distributions of strain rate of sheets and deteriorate the frictional characteristics between sheets and tools in sheet metal forming. Thus, it is important to identify the deformation behavior of these coatings to ensure the success of the sheet forming operation. In this study, the technique using nano-indentation test, FE-simulation and Artificial Neural Network(ANN) were proposed to determine the power law stress-strain behavior of coating layer and the power law behavior of extracted coating layers was examined using FE-simulation of drawing and nano-indentation process. Also, deep drawing test was performed to estimate the formability and frictional characteristic of coated sheet, which was calculated using the linear relationship between drawing force and blank holding force obtained from the deep drawing test. FE-simulations of the drawing process were respectively carried out for single-behavior FE-model having one stress-strain behavior and for layer-behavior FE-model which consist of coating and substrate separately. The results of simulations showed that layer-behavior model can predict drawing forces with more accuracy in comparison with single-behavior model. Also, mean friction coefficients used in FE-simulation signify the value that can occur maximum drawing force in a drawing test.