• 소성∙가공
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• 제20권3호
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• pp.206-213
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• 2011

A flexible die, which is composed of a number of punches with adjusted heights to form a three-dimensional curved surface, is a crucial part of a flexible forming technology. In this study, the punch and control system of the flexible die were designed. The flexible die is divided into three modules, namely, punch, control and joint, and the corresponding modules were developed. The punch module materializes a three-dimensional forming surface by the control module, which is composed of an AC servo motor set and a linear guide. The joint module is necessary for the sequential motion between the servo motor set and the punch module. A sequential motion algorithm for the AC servo motor set, that uses the data of the punch relative heights, was also proposed. Finally, a flexible stretch forming test was carried out using the presently designed flexible die.

• 대한기계학회논문집
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• 제13권6호
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• pp.1092-1103
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• 1989

본 논문에서는 기존의 금속성형의 유한요소해석에서 사용한 바 있는 기하적경 계조건을 직접 유한요소방정식에 대입하는 방법들을 비교검토하고 3차원박판성형에 적용하기 위하여 개선된 방법을 개발하였다.

• 소성∙가공
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• 제9권4호
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• pp.379-388
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• 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.

• 소성∙가공
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• 제13권6호
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• pp.528-534
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• 2004

In order to find the effect of lubricant viscosity, tool geometry, forming speed, and sheet material properties on the friction in the sheet metal forming, friction tests were performed. Friction test results show that as the lubricant viscosity becomes lower, the friction coefficient is higher. When surface roughness is extremely low or high, the friction coefficient is high. The bigger die corner radii and punch speed are, the smaller is the friction coefficient. From the experimental observation, the friction model which is the mathematical expression of friction coefficient in terms of lubricant viscosity, roughness and hardness of sheet surface, punch corner radius, and punch speed is constructed. By comparing the punch load found by FEM using the proposed friction model with that obtained from the experiment in 2-D stretch forming, the validity and accuracy of the friction model are demonstrated.

• 소성∙가공
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• 제25권3호
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• pp.161-168
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• 2016

Sheet metals are often required to be formed into three dimensional curved shapes for use as skin structures. As a result various sheet metal forming methods, such as press die forming, stretch forming, and line heating have been used over the years in industrial production lines. Although they are extensively used in industry, these methods are not suitable for small quantity batch productions. Studies have been conducted to improve or replace these methods with plausible flexible forming technologies. As a part of these studies, we developed a new and more efficient forming device named flexibly-reconfigurable roll forming (FRRF). The current study presents the process development and experimental verification for the applicability of this device. To improve the efficiency of the FRRF apparatus, several hardware components were invented and a suitable operating program was developed using MFC of visual C++. The ways to make the FRRF apparatus fully functional are also described. Sheet metal was formed into three dimensional shapes using the FRRF apparatus and the final products are presented as evidence for the applicability of the developed device.

• 소성∙가공
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• 제6권4호
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• pp.279-290
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• 1997

The sectional forming analysis of stamping pocesses for aluminum alloy sheet metals was investigated. For the modeling of the anomalous behavior of aluminum alloy sheet. the Barlat's strain rate potential and Hill's 1990 non-quadratic yield theory with an isotropic hardening rule were employed. The rigid-viscoplastic FEM formulation which solves equilibrium equation for plane-strain stage with mesh-normal geometric constraints was derived. A new method to determine the Barlat's anisotropic coefficients was also suggested. To verify the validity of the formulation, the stretch and draw forming processes of a square cup were simulated.

• 소성∙가공
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• 제1권1호
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• pp.95-103
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• 1992

The plane strain analysis for simulating the stretch/draw forming operation with an arbitrarily-shaped tool profile is introduced. An implicit, incremental, updated Lagrangian formulation with a rigid-viscoplastic constitutive equation is employed. Contact and friction are considered through the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshes without depending on the explicit spatial derivatives of tool surfaces. The linear line elements are used for depicting the formed sheet, based on membrane approximation. The FEM formulation is tested in the sections of automotive inner panel and two-side draw-in. Not only the excellent agreement between measured and computed strains is obtained in the stretched section, but also the numerical stability of formulation is verified in the draw-in section.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1994년도 박판성형기술의 진보
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• pp.147-162
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• 1994

Generally, the forming process of sheet metal is very complex and difficult process because of many variables such as tool geometry, material properties and lubrication. In this view point, the numerical analysis of sheet metal forming process is very difficult. High speed computer is used to model complex sheet metal forming process on a reasonable time scale. The design and development of sheet metal parts in the automotive industry and the need for improved sheet forming process and reduced part development cost have led to the use of computer simulation in tool/die design of sheet metal pressing. HMC(Hyundai Mator Company) has invested to develop programs for analysis of sheet metal forming process with connection of Universities. As a result, several programs were developed. Recently, the commercial software, PAM-STAMP of ESI was installed and is being tried to application of it to the real automotive panels. This article reviews the ongoing activities on development and application of analytical modeling of sheet metal forming at HMC.

• 소성∙가공
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• 제11권8호
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• pp.668-675
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• 2002

The circles deform into various shape during deformation, the major and minor axes of which indicate the direction of the major and minor principal strains. Likewise, the measured dimensions are used to determine the major and minor principal strain magnitudes. This circular grid technique of measuring strains can be used to diagnose the causes of necking and fracture in industrial practice and to investigate whether these defects were caused by material property variation, changes in lubrication, of incorrect press settings. In non-axisymmetric deep drawing, three modes of forming regimes are found: draw, stretch, plane strain. The stretch mode for non-axisymmetric deep drawing could be defined when the major and minor strains are positive. The draw mode could be defined when the major strain is positive and minor strain is negative, and plane strain mode could be defined when the major strain is positive and minor strain is zero. Through experiments the draw mode was shown on the wall and flange are one of a drawn cup, while the plane strain and the stretch mode were on the punch head and the punch corner area respectively, We observed that the punch load of elliptical deep drawing was decreased according to increase of die corner radius and the thickness deformation of minor side was more large than major side.

• 소성∙가공
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• 제4권4호
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• pp.365-374
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• 1995

Numerical simulation of blade forming is carried out as stretch forming by an elasto-plastic finite element method. The method adopts a Lagrangian formulation, which incorporates large deformation and rotation, with a penalty method to treat the contact boundary condition. Numerical integration is done with a directional reduced integration scheme to avoid shear locking. The numerical results demonstrates various final shapes of blades which depend on the variation of the stretching force. The strain distributions in deformed blades are also obtained with the variation of the stretching force.