• 소성∙가공
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• 제13권5호
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• pp.409-414
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• 2004

TRIP steel has got attention in automobile industry because of its high strength and high formability. However, the information on deformation behavior of TRIP steel, including bending and springback, is not enough until now. In this research, the V-die bending experiment and analysis have been done to obtain the information of springback of TRIP steel. And a new numerical method, where elastic modulus is varied with the change of the strain, was suggested. Tensile test for TRIP steel was done to get tensile properties as well as strain dependency of elastic modulus of the material. Strain-dependency of elastic modulus was used the numerical analysis of V-die bending and unbending process to predict springback amount. The results were compared with experiment, showing reasonable agreement. Through the analysis of V-die bending as well as draw bending of TRIP steel, the proposed scheme with variable elastic modulus was proven to well predict the deformation behavior of TRIP steel during bending and springback.

• Design & Manufacturing
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• 제15권3호
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• pp.19-25
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• 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.

• Design & Manufacturing
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• 제12권3호
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• pp.31-35
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• 2018

In this paper, the method of improving the flatness and perpendicularity for a corner fixing bracket of the large display frame is studied through experiments. Three specimens were tested, one specimen not subjected to bending line before bending, and two specimens with a straight groove with 0.2 mm and 0.5 mm depth. Experimental results show that the flatness of bracket becomes worse with deeper depth. When there is no straight groove, the perpendicularity becomes worse. For the flatness correction, a restriking process was added. The twist of bracket was corrected by performing the restriking with a curvature larger than the twist amount in the direction opposite to the deformed direction. We also found that the perpendicularity is maintained regardless of the amount of curvature with the restriking process.

• 한국산학기술학회논문지
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• 제18권2호
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• pp.349-355
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• 2017

프레스금형(press dies)에 의한 굽힘가공(bending work) 이라는 것은 평평한 블랭크(blank)를 필요로 하는 각도(角度)로 굽히는 것이다. 굽힘가공을 하면 굽혀진부분(flange)과 굽혀지지 않은 부분(web)으로 구분되며, 굽힘라인(bending line) 부분에는 굽혀진 각도(bending angle)와 굽힘반지름(bending radius)이 내측과 외측으로 성형된다. 이때, 내측 굽힘반지름의 크기는 제품의 재질별로 최소치수가 제시 된다. 제시된 최소치수 보다 작게 굽히면 절단면 굽힘부위에 덧살이 발생 하거나 외측 굽힘반지름 부위에는 균열(crack)이 생긴다. 굽힘가공에서의 외측 굽힘반지름은 자연적으로 생긴다. 그래서 외측 굽힘반지름 치수를 굽힘펀치와 다이블록으로 조정하면서 필요한 치수로 굽힐수 없다. 굽힘가공에는 V-굽힘, U-굽힘, Z-굽힘, O-굽힘, P-굽힘, 에지굽힘(edge bending), 트위스트굽힘(twist bending), 크림핑(crimping) 등이 있다.이 중에서 Z-굽힘은 굽힘라인이 2개로써 블랭크의 상면(上面)과 하면(下面)에 설정하여 상향(上向)굽힘이나 하향(下向)굽힘으로 작동되는 금형을 사용한다. Z-굽힘을 크랭크굽힘(crank bending) 이라고도 한다. 이런 구조의 금형으로 Z-굽힘가공을 하면 내측반지름은 표준치수로 굽혀진다. 표준치수라는 것은 굽힘가공에서 굽힐 수 있는 최소 굽힘반지름 치수로서 굽힘펀치의 각(角)반지름(Rp)를 뜻한다. 그런데 산업현장에서는 외측 굽힘반지름 치수를 굽힘펀치와 다이블록으로 굽힐수 없는 미세한 샤프에지(sharp edge) 형상인 매우 작은 치수(R=0.2mm)를 필요로하고 있는 바, 본 논문에서는 외측 굽힘반지름 치수를 0.2mm 이하로 굽힐수 있는 Z-굽힘가공 공법을 개발 하고자 하였다.

• 한국기계가공학회지
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• 제8권2호
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• pp.60-68
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• 2009

The objective of this paper is to design stamping die of inner reinforcement panel with DL 950 advanced high strength steel as stamping materials through numerical analyses and experiments. The stamping process was designed as bending dominant process consisting of 1 step of notching and 4 steps of bending processes. In order to obtain a proper design of the stamping die, various three-dimensional elasto-plastic finite element analyses were performed using a commercial code AUTOFORM V4.2. Design parameter of stamping die was chosen as the corner radius of the stamping die for each step. From the results of the FE analysis, feasible corner radii of the stamping die, which can minimize the deviation of corner angle of the stamped part from design data, and forming load for each part were estimated. Stamping experiments were carried out using the manufactured stamping die according to the proposed die design. The results of experiments were shown that the stamping die can successfully manufacture the inner reinforcement panel with DL 950 advanced high strength steel as base stamping material.

• 한국CDE학회논문집
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• 제9권4호
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• pp.373-381
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• 2004

Using standard components of a press die is recognized as a way for a cost reduction and a short lead time. It also provides a way for a quick maintenance of a die under repair. It is expected to contribute to integration of CAD/CAM system for manufacturing dies in the future. This paper presents a 3D CAD library which is constructed using the standard components and is used for designing a press die. This 3D CAD library is generated by a database system made of Microsoft Access for standard components and by CATIA V5 R10 API for geometric features. The library is implemented using Visual Basic 6.0 utility of CATIA API function in the Windows NT environment. It creates a 3D model of the standard components of press die easily when a die designer inputs numerical values of geometric features and the BOM of the completely assembled parts. It also generates automatically the assembly drawing of die set by using variables for standard values of die parts. Therefore users can save the cost of time to design the press die components, and even a beginner can use this program with ease. The test results of the 3D CAD library for designing shearing and bending dies verify its usefulness and feasibility.

• Design & Manufacturing
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• 제15권1호
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• pp.21-25
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• 2021

When the product is removed from the mold after molding during the sheet metal molding process, elastic recovery causes a springback phenomenon. Much research has been done to minimize this phenomenon. In this study, V-bending experiments were conducted using galvanized steel sheets, stainless steel, and aluminum sheet materials, using a total of nine types of thin sheet materials of 1.0t, 1.5t, and 2.0t, respectively. Molding analysis and experimental data were compared and analyzed. In the case of galvanized steel sheets, it was considered that the springback phenomenon occurs more frequently in molding analysis than in experiments. It was considered that the springback phenomenon occurs greatly in the experiment, not the interpretation of the molding of the stainless steel plate and the aluminum plate. It was considered that the springback occurrence tendency of the molding analysis and the experiment was the same, and the springback occurrence error rate of the molding analysis and the experimental result was about 4.0%.

• 한국자동차공학회논문집
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• 제5권6호
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• pp.64-76
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• 1997

This paper deals with development of brackets by using aluminum alloy sheets which is indispensable for weight reduction of autobody. The press formability of aluminum alloy sheet is estimated by means of tensile test, V bending test, sample manufacturing test and photograph of microstructure. The results show that the elongation, strength, work hardening exponent, plastic anisotropy coefficient of Al 6***series are better than those of Al 5***series, but for general press formability, Al 5***series are better than Al 6***series due to lower yield strength. Since most of mechanical properties of aluminum sheet are generally inferior to those of cold-rolled steel sheet, shape fixability and press formability of aluminum sheet are very poor. For making components of autobody by use of die for steel sheet application, it is essential that die should be nodified for least bending and stretching. With the modified die for aluminum, it could be possible to make brackets, the component of autobody. Microstructure of Al 5***series has fine grain and small the 2nd phase and that of Al 6***series has relatively coarse grain. Therefore, it seems that fine grain and small the 2nd phase of Al 5***series is one of the factor of lower yield strength, resistance to stamping work, formation of Luder's line.

• 소성∙가공
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• 제23권8호
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• pp.469-474
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• 2014

With the increased concerns of environmental issues, industries are paying more attention to lightweight metals. Because the high degree of springback is an obstacle to the widespread use of lightweight metals, many investigations have been conducted to reduce springback by increasing temperature. However, increasing the temperature of the whole die or the material is energy inefficient, since generally only a limited area of the material is deformed during sheet metal forming. As a solution to this problem, focused heating that only heats the area where plastic deformation occurs may be an alternative approach. In the current study, V-bending tests were conducted at various temperatures after the AZ31, Ti-GR2 sheets were locally heated using near-infrared (NIR) radiation in order to evaluate the effect of temperature on springback. The results of the experiment confirm that the NIR focused heating reduces the springback of AZ31, Ti-GR2 alloys with increasing temperature.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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• pp.47-52
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• 2004

Springback comes from the release of residual stress after forming. The control of phenomenon is especially important in the sheet metal forming since there are no other practical methods available to correct the dimensional inaccuracy from springback. Therefore the accurate predication before the die machining has been a long goal in the Held of sheet metal forming. The aim of the present study is to enhance the prediction capability of finite element(FE) analysis for the springback phenomenon. For this purpose FE analysis for V-bending has been carried out with the commercial programs, LS-DYNA. The FE analysis results have been validated through the comparison of experimental. The experimental results measured directly by the strain gauge have given the confidence to FEA.