• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2001.10a
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• pp.253-257
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• 2001

This study reveals the sheet metal working with multi-forming type ultra precision process. They require analysis of many kinds of important factors, i.e. theory and practice of metal press working and its phenomena, die structure, machining condition for die making, die material, heat treatment of die components, know-how and so on. In this study, we designed and constructed a multi-forming ultra precision progressive die as a bending and drawing working of multi-stage and performed through the try out for thin sheet metal. This part I of papers related to the analysis of production part and strip process layout design through the metal forming simulation by DEFORM and IDEAS.

• Transactions of Materials Processing
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• v.29 no.4
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• pp.194-202
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• 2020

In this paper, experimental and numerical study on a combined sheet metal forming and plate forging of a seal part of a passenger car's hub bearing is conducted to develop the new process of which target is to remove machining process by plate forging and to achieve near-net shape manufacturing. The previous process of a sheet metal forming inevitably needed a machining process for making stepped sheet after conventional sheet metal forming in a progressive way. The stepped sheet is intended to be formed by plate forging in this study. Through the systematic way of developing the combined forming process using solid elements based-elastoplastic finite element method (FEM), several conceptual designs are made and an optimized process design in terms of geometric dimensioning and tolerance of straightness of the thin part is found, which is exposed to bending in metal forming of axisymmetric part. The predicted straightness measured by the slope angle of the tilted thin region is compared with the experimental straightness, showing that they are in a good agreement with each other. Through this study, a systematic approach to optimal process design, based on elastoplastic FEM with solid elements, is established, which will contribute to innovating the conventional small-scaled sheet metal forming processes which can be dealt with by solid elements.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.318-321
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• 2005

The shell part is made of 2-layered blank because of functional requirements. To investigate the draw formability in this kind of part, the 2-layered sheet metal forming analysis process should be stipulated. First of all, treatment of contact with each blank must be considered to prevent the penetration on the each blank. Subsequently, applying the draw bead force is considered carefully because application of drawbead force for analysis is different with equivalent drawbead force. Formability as like crack, neck and wrinkles is estimated by FLD(Forming Limit Diagram) and thinning. A feasibility of the 2-layered sheet metal forming analysis process study is verified compare 2-layered sheet metal forming analysis with experimental results.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.224-228
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• 2000

The piercing and blanking of thin sheet metal working is specified division in press die design and making. In order to prevent the detects, the optimum design of the production part, strip process layout, die design, die making and try out etc. re necessary the analysis of effective factors. For example, theory and practice of metal shearing process and its phenomena, die structure, machine tool working for die making, die materials and its heat treatment, metal working in industrial and its know how etc. In this study, we analyzed whole of data base, theoretical back ground of metal working process, and then performed the progressive die tryout with the screw press. This study regards to the aim of small quantity of production part's press working. Part 1 of this study reveals with production part and strip process layout design.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.4
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• pp.696-706
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• 1992

In sheet metal fabrication using NCT(numerically controlled turret), the automatic tool selection for the NCT operation is the major problem to be solved first to improve its production performance. However, the punching tool selection has been done by human experts either manually or semi-automatically. In this paper, we have introduced the shape-index-set to handle the shape of sheet metal parts and developed an algorithm through which one can find easily the successive matching curves between two curve lists, one from the punching tool and the other from the boundaries of the sheet metal part. Based on this algorithm, we have also devised the method that can select automatically the tools to punch out the boundaries of sheet metal parts. The result of several computational experiments shows the successful tool selection without any fail.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2000.10a
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• pp.109-113
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• 2000

The piercing and blanking of thin sheet metal working with a pilot punch guide is specified division in press die design and making. In order to prevent the detects, the optimum design of the production part, strip process layout, die design, die making and try out etc. are necessary the analysis of effective factors. For example, theory and practice of metal shearing process and its phenomena, die structure, machine tool working for die making, die materials and its heat treatment, metal working in industrial and its know how etc. In this study, we analyzed whole of data base, theoretical back ground of metal working process, and then performed the progressive die tryout with the screw press. This study regards to the aim of small quantity of production part's press working by piloting for accurate guide of actual sheet metal strip. Part 1 of this study reveals with production part and strip process layout for the die design.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.46-49
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• 1997

During sheet metal forming on a double-action press, drawbeads on the blankholder supply a restraining force which controls the flow of metal into the die. The sheet formability can be improved by the optimum drawbeads installation when the punch enters into the die opening. Experiments on the various drawbeads, circular, step, double circular, and circular-step drawbead, have been performed under various working conditions.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2000.04a
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• pp.35-39
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• 2000

The piercing and blanking of thin sheet metal working is specified division in press die design and making. In order to prevent the detects, the optimum design of the production part, strip process layout, die design, die making and try out etc. are necessary the analysis of effective factors. For example, theory and practice of metal shearing process and its phenomena, die structure, machine tool working for die making, die materials and its heat treatment, metal working in industrial and its know how etc. In this study, we analyzed whole of data base, theoretical back ground of metal working process, and then performed the progressive die tryout with the screw press. This study regards to the aim of small quantity of production parts press working. Part 1 of this study reveals with production part and strip process layout design.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.349-354
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• 2002

In order to find the effect of lubricant viscosity, sheet surface roughness, tool geometry, and forming speed on the frictional characteristics in sheet metal forming, a sheet metal friction tester was designed and manufactured and friction test of various sheet were performed. Friction test results showed that as the lubricant viscosity becomes lower, the friction coefficient is higher. When surface roughness is extremely low or high, the friction coefficient is relatively high. The result also show that as the punch radius and punch speed becomes bigger, the friction coefficient is smaller. Using experimental results, the mathematical expression between friction coefficient and lubricant viscosity, surface roughness, punch comer radius, or punch speed is also described.

• Transactions of Materials Processing
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• v.11 no.6
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• pp.503-512
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• 2002

The drawbead is used to control material flow into the die during the binder wrap process and the stamping process in the sheet metal forming process. Since the dimension of drawbead is relatively small in comparison with the typical dimensions, it is difficult to include drawbeads in finite element analysis of the sheet metal forming process. It is because the mesh system has to be fine enough to describe the drawbead and the computation time is drastically increased. In this paper, simulation of drawbead forming has been carried out to obtain the equivalent boundary conditions in the binder wrap process and the stamping process. In order to investigate the effect of various die geometries, parameter studies are performed with the variation of parameters such as the blank length, the drawbead depth, the drawbead radius, the inclination of die and the friction coefficient.