• 대한기계학회논문집A
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• 제26권11호
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• pp.2262-2269
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• 2002

Process optimization is carried out to determine process parameters which satisfy the given design requirement and constraint conditions in sheet metal forming processes. Sensitivity -based-approach is utilized for the optimum searching of process parameters in sheet metal forming precesses. The scheme incorporates an elasto-plastic finite element method with shell elements . Sensitivities of state variables are calculated from the direct differentiation of the governing equation for the finite element analysis. The algorithm developed is applied to design of the variablc blank holding force in deep drawing processes. Results show that determination of process parameters is well performed to control the major strain for preventing fracture by tearing or to decrease the amount of springback for improving the shape accuracy. Results demonstrate that design of process parameters with the present approach is applicable to real sheet metal forming processes.

• 한국정밀공학회지
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• 제33권4호
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• pp.247-255
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• 2016

Sheet metal-forming processes such as stamping, deep drawing, bending, shearing, hydroforming, hydromechanical deep drawing, rubber forming, and incremental forming have been widely used in the automotive, aircraft, and ship-building industries. With the expansion of the automotive industry, research on these processes has been remarkably developed in Korea since the 1980s. Here, we review the history of this research as well as recent trends in sheet metal-forming processes. This overview focuses specifically on the results of research in Korea and on the works of Professor D.Y. Yang, in honor of his retirement.

• 한국CDE학회논문집
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• 제9권2호
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• pp.133-142
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• 2004

CAMPfonn2D is a Finite Element Method (FEM) based process simulation system designed to analyze two dimensional (2D) flow of various metal forming processes. It enables designers to analyze metal forming processes on the computer rather than the shop floor using trial and error and provides vital information about material and thermal flow during the forming process to facilitate the design of products. CAMPfonn2D can be used by companies, research institutes and industrial applications to analyze forging, extrusion, drawing, heading, upsetting and many other metal forming processes. Also, process simulation using CAMPfonn2D can be instrumental in cost, quality and delivery improvements at leading companies. Today's competitive pressures require companies to take advantage of every tool for rapid manufacturing of well-designed product. So, the preprocessor of simulation program must be easy to use to speed-up design. In this paper, we introduce new version of Preprocessor and show how easy to use it. And, Preprocessor will prove itself to be easy and extremely effective.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2001년도 춘계학술대회논문집C
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• pp.100-105
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• 2001

The manufacturing of metal bellows consists of the four main forming processes, deep-drawing, ironing, tube bulging and folding. Among these, the bulging and folding processes are critically important because the quality of metal bellows is greatly influenced by the forming conditions of these processes. In the present study, the finite element analysis technique is applied to the bulging and folding processes to obtain information about the design parameters of a metal bellows.

• 소성∙가공
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• 제9권3호
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• pp.233-241
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• 2000

It is well known that the quality and efficiency of the design of metal forming processes can be significantly improved with the aid of effective numerical simulations. In the present study, a two-and three-dimensional finite element simulation system, CAMP form, was developed for the analysis of metal forming processes in the PC environment. It is composed of a solver based on the thermo-rigid-viscoplastic approach and graphic user interface (GUI) based pre-and post-processors to be used for the effective description of forming conditions and graphic display of simulation results, respectively. In particular, in the case of CAMPform 2D (two-dimensional), as the solver contains an automatic remeshing module which determines the deformation step when remeshing is required and reconstructs the new mesh system, it is possible to carry out simulations automatically without any user intervention. Also, the forming analysis considers ductile fracture of the workpiece and wear of dies for better usage of the system. In the case of CAMPform 3D, general three-dimensional problems that involve complex die geometries and require remeshing can be analyzed, but full automation of simulations has yet to be achieved. In this paper, the overall structure and computational background of CAMPform will be briefly explained and analysis results of several forming processes will be shown. From the current results, it is construed that CAMPform can be used in providing useful information to assist the design of forming processes.

• 소성∙가공
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• 제9권6호
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• pp.598-603
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• 2000

In order to improve trial-and-error based conventional practices for optimizing forming processes, a direct design method to guide iterative design practices, called the ideal forming theory, has been previously developed. In the theory, material elements are required to deform following the minimum Plastic work Path. The theory can be used to determine the ideal initial blank shape needed to best achieve a specified final shape while resulting in optimum strain distributions. In this work, the direct design method based on the ideal forming theory was applied to design initial design shape for VCR deck chassis. Based on the solution of the ideal forming theory, FEM analysis was utilized to evaluate an optimum blank shape to be formed without tearing. Simulation results are in good agreement with experimental data. It was shown that the proposed sequential design procedure based on direct design method and FEM can be successfully applied to optimize the die design Procedure of sheet metal forming processes.

• 소성∙가공
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• 제9권3호
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• pp.284-292
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• 2000

Optimization of the process parameters is carried out for process design in sheet metal forming processes. The scheme incorporates with a rigid-plastic finite element method for the deformation analysis and response surface methodology for the optimum searching of process parameters. The algorithm developed is applied to design of the draw bead force and the die radius in deep drawing processes of rectangular cups. The present algorithm shows the capability of designing process parameters which enable the prevention of the weak part of fracture during processes.

• 한국기계가공학회지
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• 제12권1호
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• pp.90-96
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• 2013

During the cold forming, due to high working pressure acting on the die surface, failure mechanics must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. Die wear affects the tolerances of formed parts, metal flow and costs of process etc. The only way to control these failures is to develop methods which allow prediction of die wear and which are suited to be used in the design state in order to optimize the process. In this paper, the wear experiments to obtain the wear coefficients and the upsetting processes was accomplished to observe the wear phenomenon during the cold forming process. The analysis of upsetting processes was accomplished by the rigid-plastic finite element method. The result from the deformation analysis was used to analyse the die wear during the processes and the predicted die wear profiles were compared with the measured die wear profiles.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1994년도 박판성형기술의 진보
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• pp.25-36
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• 1994

The sheet metal forming process is one of the most important manufacturing processes in the modern industry. From the view point of mechanics involved, it is very difficult to predict whether a newly designed sheet metal part can be formed without defects such as fracture, wrinkling and surface unevenness, etc. In order to reduce the effort taken in the trial-and-error process and to control the process effectively, a systematic method for process modeling is to required. The aim of sheet forming simulation through the process modeling is to reduce the lead time for die disign and manufacture by process modeling is to reduce the lead time for die design and manufacture by means of investigating the deformation mechanics and the mutual interaction between the process parameters. In this paper, the necessity, the present status, and the future technology about CAE of sheet forming simulation have been discussed.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 춘계학술대회논문집
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• pp.141-145
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• 2000

A systematic method to find the optimal blank shape for sheet forming is proposed by coupling the numerical simulation technique. A weighted parameter was introduced in order to simplify the multi-variable optimization problem to a single-variable problem. The proposed method has been applied to the blank design of drawing processes to obtain the near-net shape within the required error bound after forming, Excellent results have been obtained between the numerical results and the target contour shapes. Through the investigation the proposed systematic method for optimal blank design is found to be effective in the practical forming processes