• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.14 no.1
• /
• pp.28-32
• /
• 2013

In this study, we suggested new method for compensation on spring back of press part. At first, we compared between error on CAD data and scanning data. The new method can be substituted for manual modeling process in compensation on spring back. The new method is available for automatic modeling based on 3D scanning data. From the study, the results expect that time and cost reduction for process applying new method for compensation on spring back of press part.

• Transactions of Materials Processing
• /
• v.21 no.7
• /
• pp.397-402
• /
• 2012

The flange hub is a main component in an automotive steering system. In general, the flange hub are fabricated by mechanical machining, which is a process where material waste is inevitable. It is well-known that a net-shape cold forging cannot only reduce material waste but can also improve the mechanical strength of the final product. Thus, a forging process design was conducted for production of a flange hub. Significant spring-back occurs around the flange due to its small thickness in conjunction with the residual stresses after forging. In order to achieve the required dimensional accuracy, a process design with appropriate spring-back control is needed. In this study, a modification of the forging die was designed based on FE analysis with the purpose of spring-back compensation. Four kinds of different die designs were evaluated and the optimum design has two times less spring-back than the initial design. The compensation angle of the optimum design is 0.5 degrees. The results have been experimentally confirmed by cold forging of a flange hub and comparing the amount of spring-back between the actual component and the FE analysis.

• Journal of Ocean Engineering and Technology
• /
• v.22 no.6
• /
• pp.75-82
• /
• 2008

Flame bending has been extensively used in the shipbuilding industry for hull plate forming In flame bending it is difficult to obtain the desired shape because the residual deformation dependson the complex temperature distribution and the thermal plastic strain. Mechanical bending such as reconfigurable press forming multi-point press forming or die-less forming has been found to improve the automation of hull plateforming because it can more accurately control the desired shape than line heating. Multi-point forming is a process in which external forces are used to form metal work-pieces. Therefore it can be a flexible and efficient forming technique. This paper presents an optimal approach to determining the press-stroke for multi-point press forming of curved shapes. An integrated configuration of Finite element analysis (FEA) and spring-back compensation algorithm is developed to calculate the strokes of the multi-point press. Not only spring-back is modeled by elastic plastic shell elements but also an iterative algorithm to compensate the spring-back is applied to adjust the amount of pressing stroke. An iterative displacement adjustment (IDA) method is applied by integration of the FEA procedure and the spring-back compensation work. Shape deviation between the desired surface and deform￡d plate is minimized by the IDA algorithm.

• Journal of the Society of Naval Architects of Korea
• /
• v.48 no.6
• /
• pp.528-538
• /
• 2011

As a forming method for curved hull plates more efficient than the flame bending, mechanical bending using multi point press forming and die-less forming is discussed in this paper. the mechanical forming is a flexible manufacturing system for automatically forming of hull parts. It is especially suited to varied curved parts. This paper discusses a multiple point pressing machine composed of a pair of reconfigurable punches in order to achieve the rapid forming of curved hull plates using division forming and presents how forming information is obtained from the given design surface. Although the mechanical forming can be efficient in the metal forming, spring back after pressing is a phenomenon which must be carefully considered when quantifying the process variables. If the spring back is not accurately controlled, the fabricated shell plate cannot meet assembly tolerance. This paper describes the principles to calculate the proper stroke of each punch at the divided areas. the strokes are determined by an iterative process of sequential pressing and spring back compensation from an unfolded flat shape to its given design surface. FEA(finite element analysis) is used to simulate the spring back of the plate and the IDA(iterative displacement adjustment) method adjusts the offset of pressing punches from the deformation results and the design surface. The shape deviations of two surfaces due to spring back are compensated by integrated system using FEA and IDA method. For the practical application, It is aimed to develop an integrated system that can automatically perform the compensation process and calculate strokes of punches of the double sides' reconfigurable multiple-press machine and some experimental results obtained with mechanical bending are presented.

• Composites Research
• /
• v.19 no.1
• /
• pp.29-35
• /
• 2006

The avoidance of enemy's radar detection is very important issue in the modem electronic weapon system. Researchers have studied to minimize reflected signals of radar. In this research, two types of radar absorbing structure (RAS), 'C'-type shell and 'U'-type shell, were fabricated using fiber-reinforced composite materials and their radar cross section (RCS) were evaluated. The absorption layer was composed of glass fiber reinforced epoxy and nano size carbon-black, and the reflection layer was fabricated with carbon fiber reinforced epoxy. During their manufacturing process, undesired thermal deformation (so called spring-back) was observed. In order to reduce spring-back, the bending angle of mold was controlled by a series of experiments. The spring-back of parts fabricated by using compensated mold was predicted by finite element analysis (ANSYS). The RCS of RAS shells were measured by compact range and predicted by physical optics method. The measured RCS data was well matched with the predicted data.