• Korean Journal of Computational Design and Engineering
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• v.14 no.2
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• pp.129-136
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• 2009

Generally, curved surfaces of ship hull are deformed by flame bending (line heating), multi-press forming, and die-less forming method. The forming methods generate the required in-plane/bending strain or displacement on the flat plate to make the curved surface. Multi-press forming imposes the forced displacements on the flat plate by controlling the position of each pressing points based upon the shape difference between the unfolded flat plate and the curved object shape. The flat plate has been obtained from the unfolding system that is independent of the ship CAD. Apparently, the curved surface and the unfolded-flat surface are expressed by different coordinate systems. Therefore, one of the issues is to find a registration of the unfolded surface and the curved shape for the purpose of minimum amount of forming works by comparing the two surfaces. This paper presents an efficient algorithm to get an optimized registration of two different surfaces in the multi-press forming of ship hull plate forming. The algorithm is based upon the ICP (Iterative Closest Point) algorithm. The algorithm consists of two iterative procedures including a transformation matrix and the closest points to minimize the distance between the unfolded surface and curved surfaces. Thereby the algorithm allows the minimized forming works in ship-hull forming.

• Journal of the Society of Naval Architects of Korea
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• v.56 no.2
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• pp.128-134
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• 2019

In shipbuilding, accurate fabrication of curved hull plates is one of the most important steps, since the shape of ship hull, which is very critical in the overall performance of a ship, is a collection of such plates. The curved hull plates forming process requires a significant amount of time by skilled workers in shipbuilding. In general, the workers cause thermal distortion in the plate and forming initial shape using gas heat source. So shipbuilding companies need skilled workers who have long experience. To solve the problem, a lot of researchers tried to develop automation system for curved hull plates. In this paper, we propose automatic heating system with gantry robot, high frequency induction heater to replace the gas heat source and automatic measurement system. We apply the system to forming concave type plate that is actually used in ship manufacturing. In addition, a system was developed to automatically generate heating information, such as the heating location and the heating speed, for actual heating process. Then the system was applied to the actual heating material. It is shown that the proposed triangle heating pattern makes desired concave shape successfully. The induction heating system showed that it can be used for automation system of curved hull plates forming process replacing gas heat source.

• Journal of Welding and Joining
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• v.27 no.2
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• pp.32-37
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• 2009

In shipyard, plate forming is widely used to form the ship hull plate in various shapes. Line heating method by using a flame torch is one of the major shipbuilding processes carried out by skilled workers. Since the forming characteristics depend upon their experiences in manual forming, there are much variations between products and difficulties in communication between engineers and workers. Hence, it needs to develop an automatic forming system which can not only reduce the working time and rework costs but also improve the working environment and hull forming productivity. One of the final goals of plate forming automation is to form a target shape from the initial plate automatically. For automated plate forming, it is required to determine where and how to heat on the plate. To realize this procedure, the inverse problem should be first solved and the effect of curvature shape formed at the heating path should be investigated. In this study, the inverse problem was solved by geometrical approach using the relationship between bending angle and radius of curvature of the curved shape. In addition, experiments of two-dimensional plate forming were performed with the distance-based method considering the curved bending with curvature. The result of the formed shape agreed considerably well with the target shape.

• Journal of the Korean Society of Systems Engineering
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• v.4 no.2
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• pp.1-13
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• 2008

The development of hull curved plate forming automation system in ship production field begins from the need of stakeholders such as enterprise organization, who need the reduction of cost and time and improvement of productivity, and end users who work for this production process. Even though hull curved plate forming automation system has small scale, it is reasonable to consider the system as an interdisciplinary system, because the system includes all of hardware, software, human and information and has a specified objective to be performed. In this paper, introduction of 4 leading Model-Based Systems Engineering (MBSE)methodologies is described and SysML(Systems Modeling Language), which is designed to analyze, specify, design, and verify complex systems, is introduced in order to support those methodologies. Especially, SysML is applied to system modeling of hull curved plate forming automation system and focused on. The structure diagrams and behavior diagrams based on operational context of the automation system are used to make system architecture. The performed application of SysML to the hull curved plate forming automation system shows an example of applying SysML to the development of other autonomous systems in ship production domain.

• 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.

• Journal of the Society of Naval Architects of Korea
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• v.53 no.1
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• pp.69-75
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• 2016

Fabrication of the hull plate demands a lot of man-hour and a high degree of technology. In recent years, commercial shipping orders have been fallen because of intensifying competition with low price of order and labor cost. In order to solve this problem, a countermeasure such as a cost reduction is required. In this study, we are dealing with the method of supplying the forming information of the hull to the production site. We reviewed studies of hull forming that have been proposed so far to develop a method for providing hull forming information. On the basis of given production plans from the production site of shipyard, we discuss how to convert shell plate to production plan. Then, we will discuss the efficiency of the distribution method through the network about the method of hull forming. Thus, we have modified the distribution method which was proposed before. Finally, we will introduce the enhanced method for providing fabrication information of the hull plate to the small and medium-sized shipyards.

• Proceedings of the KWS Conference
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• 2008.05a
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• pp.25-25
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• 2008

• Transactions of Materials Processing
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• v.19 no.2
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• pp.120-126
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• 2010

The line array roll set(LARS) process, as one of many kinds of incremental forming processes, is a continuous process in which a flat metal plate is formed into a singly or doubly curved plate through successive passes of forming rolls. It was found that the curvature level of the formed plates in the previous study was well over the curvature required in shipyards. This fact shows that the LARS method has good potential for shipbuilding applications. The major purpose of the present study is to estimate experimentally the general applicability of the line array roll set process for the manufacture of ship hull plates. In this study, the target shapes are selected through investigation of the shape classification of ship hull plates that comprise a certain vessel. Forming processes for twisted shapes are analyzed with the finite element method(FEM) and the results of experimental work are presented. On the basis of the experimental and numerical results, the LARS process is applied to the production of real outer hull plates of a small patrol ship.

• Transactions of Materials Processing
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• v.17 no.1
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• pp.27-34
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• 2008

In order to manufacture a doubly curved sheet metal, the incremental roll forming process which adopts advantages such as the flexibility of the incremental forming process and continuous bending deformation of the roll forming process has been experimentally investigated. An experimental equipment was developed which was named as unit roll set (URS) consisting of two pairs of support rolls and an upper center roll. The upper roll equipped with the servo control unit is motor-driven and can be positioned in the vertical direction according to the user's commands. Four support rolls are idle, and they freely rotate only along the axis so as to transfer the plate more stably in the tangential direction of the rotation of the driving roll. In the process, the plate is deformed incrementally as deformation proceeds simultaneously in longitudinal and transverse directions. Through the experiments using URS, information regarding to forming schedules is found out to fabricate curved hull plates. This study demonstrates the further application of the incremental roll forming process in shipbuilding industries.

• 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.