• Transactions of Materials Processing
• /
• v.12 no.3
• /
• pp.236-243
• /
• 2003

Maintaining the required dimensional accuracy after springback becomes the main concern of sheet-forming die designers when formability is secured through beforehand tryouts. As a part to build guidelines for springback control in automobile frame forming, experiments are carried out to show the effects of process parameters, such as holding force, blank size, and lubrication, on corner angles of channels formed by U-bending or by square-cup drawing and trimming. The results predicted by a commercial FE package were compared with the experiment and the current limitations on springback evaluation were closely discussed.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.05a
• /
• pp.874-877
• /
• 2000

Pre-coated sheet materials are a cost-effective and environmentally attractive alternative to conventional sheet materials coated after forming. At present but the high scratch sensitivity of coating used for pre-coated metal sheet is a major limitation to use of these materials. Because of high scratch sensitivity, products made by pre-coated metal sheet are not formed by conventional design method. This study has been performed to investigate scratch characteristic of non-vinyl pre-coated metal (PCM) sheet. Using the simple U-bending test equipment, three non-vinyls PCM's were tested. This paper provides the results of bending tests showing the influence of sheet surface texture, tool material and process conditions. It was found that the influence of punch, die clearance and tool material had an effect upon the scratch characteristic.

• Transactions of Materials Processing
• /
• v.25 no.3
• /
• pp.189-194
• /
• 2016

In the current study, spring-back of DP980 steel sheet was numerically evaluated for U-bending using a yield function with a hardening model. For spring-back prediction, two types of yield functions - Hill'48 and Yld2000-2d - were considered. Additionally, isotropic hardening and the Yoshida-Uemori model were used to investigate the spring-back behavior. The parameters for each model were obtained from uniaxial tension, uniaxial tension-compression, uniaxial tension-unloading and hydraulic bulging tests. The numerical simulations were performed using the commercial software, PAM-STAMP 2G. The results were compared with experimental data from a U-bending process.

• Design & Manufacturing
• /
• v.15 no.3
• /
• pp.19-25
• /
• 2021

The bending process of a press die is to bend a flat blank to the required angle. There are V-bending, U-bending, Z-bending, O-bending etc. for bending processing, and the basic principle of calculating the unfolding length of die processing is used as the neutral plane length. Since the constant of the length value of the neutral surface is different depending on the type of bending, it is impossible to accurately calculate it. In particular, Z-bending processing is performed twice, and it is set on the upper and lower surfaces of the blank, and bending processing occurs at the same time as the upward and downward bending, and the elongation of the material occurs and the material increases. It is not possible to check with the calculated value, and it occurs in many cases where the mold is modified after start-up. This study aims to minimize die modification by developing a formula to calculate the development length of Z-bend.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2004.10a
• /
• pp.1082-1086
• /
• 2004

Since the sheet forming of Mg alloy has many difficulties due to the low formability, many forming conditions need to be selected properly. Especially, the process variables should be investigated to increase the formability, such as, forming temperature. In this paper, the effects of forming process variables has been investigated using the bending and deep drawing process. A simple U-bending designed for mobile part could be formed in room temperature and springback amounts are surveyed. On the other hand, square cup part couldn't be formed in room temperature due to the low formability. Therefore, the effects of forming temperature are investigated in deep drawing process for square cup part. As a experimental and FEM results, the optimum forming temperature is presence and formability in a higher temperature is less than that of lower temperature. Above experimental results are compared with the FEM analysis and well coincided with the experimental results. Therefore, more detail investigations could be progressed to select more appropriate process conditions by the FEA.

• Steel and Composite Structures
• /
• v.15 no.2
• /
• pp.203-220
• /
• 2013

The study of the tensile strength of composite materials is far more complex than analysis of the properties of elasticity and plasticity. Indeed, during mechanical loading, micro-cracks in the matrix, the fibers break, debonding of the interfaces are created. The failure process of composites is of great diversity and cannot be described if even we know: the strength criterion of each individual component, the state of stress and strain in the material, the propagation phenomena cracks in the structure and nature of the interface between the matrix and the reinforcement. This information is only partially known and the obtained by the analysis of a stress limit beyond which there is destruction of the material is almost impossible. To partially process the issue, a solution lies in a mesoscopic approach of seeking a law to locate the ultimate strength of the material for a plane stress state. Tests on rectangular plates in bending PEEK/APC2 and T300/914 three were made and this in order to validate our approach, the calculation has been implemented in a nonlinear finite element code (Castem 2000), in order to make comparison with the numerical results. The results show good agreement between numerical simulation and the two materials; however, it would be interesting to consider other phenomena in the criterion.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.24 no.2 s.173
• /
• pp.279-289
• /
• 2000

Residual stress induced in U-bending and tube-to-tubesheet joint processes of PWR's row-1 heat exchanger tube was measured by X-ray method and Hole-Drilling Method(HDM). Compressive residual stresses(-) at the extrados surface were induced in U-bending, and its maximum value reached -319 MPa in axial direction at the position of $\psi$ = $0^{\circ}$. Tensile residual stresses(+) of $\sigma_{zz}$ = 45 MPa and $\sigma_{\theta\theta}$ = 25 MPa were introduced in the intrados surface at the position of $\psi$ = $0^{\circ}$. Maximum tensile residual stress of 170 MPa was measured at the flank side at the position of $\psi$ = $90^{\circ}$, i.e., at apex region. It was observed that higher stress gradient was generated at the irregular transition regions (ITR). The trend of residual stress induced by U bending process of the tubes was found to be related with the change of ovality. The residual stress induced by the explosive joint method was found to be lower than that by the mechanical roll method. The gradient of residual stress along the expanded tube was highest at the transition region (TR), and the residual stress in circumferential direction was found to be higher than the residual stress in axial direction.

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.12
• /
• pp.163-168
• /
• 2000

Once the chip has developed a mixed mode of side-curl and up-curl, it would generally curl to strike the tool flank. The development of the bending stresses and sheat in the chip would ultimately lead to chip failure. This paper approach this problem from a mechanics-based approach, by treating the chip as a 3-D elastic curved beam, and applying appropriate constraints and forces. The expressions for bending, shear and direct stresses are developed through an energy-based criterion. The location of the maximum stresses is also identified and explained for simulated test conditions.

• Composites Research
• /
• v.26 no.5
• /
• pp.295-302
• /
• 2013

In this study, Al5052/CFRP composites were fabricated for an automobile component by compression molding process inside a U-channel mold. Al5052 sheet were treated by sand blasting with two different particle sizes. Accordingly, surface roughness (Ra) values of $4.25{\mu}m$ and $1.85{\mu}m$ were obtained for the treated Al5052 sheets. The effect of surface roughness of Al5052 sheets on the adhesion and mechanical properties of Al5052/CFRP composites have been evaluated. Shear lap test and 3-point bending test were conducted. Results showed that the shear load for the composite fabricated by using the treated Al5052 sheets with Ra value of $1.85{\mu}m$ and $4.25{\mu}m$ were 3 and 5 times higher than Ra value of $0.73{\mu}m$ of the composite fabricated by using the untreated sheet. The bending stress of 200MPa was obtained for the composite fabricated with untreated Al5052 sheets. The bending stress increased to 400MPa when the composite fabricated from treated sheets. However, the bending stress was not influenced by treating condition through sand blasting.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2006.05a
• /
• pp.281-284
• /
• 2006

Metallic sandwich plates with hi-directional inner structure are important new structures for forming applications. Bi-directional corrugated inner structures with less than 25% of relative density are fabricated by piecewise sectional forming process and then bonded with two face sheets by adhesive bonding. Drawing and U-bending experiments have performed and shown that the radius of curvature of sandwich plates is 75mm and sandwich plates are bended 90 degrees without collapse of inner structures. Bi-directional inner structures are suggested to improve formability of sandwich plates for bending and drawing.