• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.270-273
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• 2003

The strain measurement of the panel in the sheet metal forming is essential work which provides experimental data needed to die design, process design, and product inspection. To measure efficiently the complex geometry strain, the 3-dimensional automative strain measurement system, which has high accuracy in theory, but has some 3∼5% errors in practice, is often used. The object of this study is to develop the error compensation technology to eliminate the strain, errors resulted when formed panels are measured using an automated strain measurement system. To achieve the study object, the position error calibration method correcting coordinates of the grid node recognized by a camera using error functions is suggested. Then the position errors were found by calculating the difference in the position of the cube node between real coordinates and measured coordinates in toms of node coordinates and the error calibration equations were derived by regressing the position errors. In order to show the validation of the suggested position error calibration method, finite element analysis and current calibration method was performed for the initial-blankformed.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.280-286
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• 2015

Hemming is used to connect two sheet metal components by folding the edge of an outer panel around an inner panel to create a smooth edge. The minimization of hemming defects is critical to the final quality of automobile products because hemming is one of the last operations during fabrication. Designing the hemmed part is not easy and is influenced by the geometry of the bent part. Therefore, the main problem for automotive parts is dimensional accuracy since formed products often deviate geometrically due to large springback. Few numerical approaches using 3-dimensional finite element model have been applied to hemming due to the small element size which is needed to properly capture the bending behavior of the sheet around small die corner and the comparatively big size of automotive opening parts, such as doors, hoods and deck lids. The current study concentrates on the 3-dimensional numerical simulation of hemming for an automotive door. The relationship between the design parameters of the hemming operation and the height difference defect is shown. Quality improvement of the automotive door can be increased through the study of model parameters.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 1998.04a
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• pp.444-449
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• 1998

A modal transducer in two-dimensional structure can be implemented by varying the distributed transducer's gain spatially. In this paper, a method based on finite element method is developed for optimizing spatial gain distribution of PVDF transducer to create the modal transducer for specific modes. Using this concept, one can design the modal transducer in two-dimensional structure having arbitrary geometry and boundary conditions. As a practical means for implementing this continuous gain distribution without repoling die PVDF film, the gain distribution is approximated by optimizing gain-weights of interface circuit. The whole spatial area of the PVDF film is divided into several electrode segments and the signals from each segment are properly weighted and summed by interface circuit. This corresponds to the approximation of a continuous function using discrete values. The electrode partition is optimized using the genetic algorithm. Gain-weights are optimized using the simplex search method. A modal sensor for first to fourth modes of aluminum plate is designed using PVDF film with gain-weighted interface circuit. Various lamination angles of PVDF film are taken into consideration to utilize the anisotropy of the PVDF film. Performance of the optimized' PVDF sensor is demonstrated by numerical simulations..

• Journal of the Korean Society for Precision Engineering
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• v.20 no.10
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• pp.31-40
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• 2003

In this paper, optimal cutting condition to minimize the form error in side wall machining with a flat end mill is studied. Cutting forces and tool deflection are calculated considering surface shape generated by the previous cutting such as roughing. Using the form error prediction method from tool deflection, optimal cutting condition considering form accuracy is investigated. Also, the effects of tool teeth number, tool geometry and cutting conditions on form error are analyzed. The characteristics and the difference of generated surface shape in up and down milling are discussed and over-cut free condition in up milling is presented. Form error reduction method through successive up and down milling is also suggested. The effectiveness and usefulness of the presented method are verified from a series of cutting experiments under various cutting conditions. It is confirmed that form error prediction from tool deflection in side wall machining can be used in optimal cutting condition selection and real time surface error simulation for CAD/CAM systems. This study also contributes to cutting process optimization for the improvement of form accuracy especially in precision die and mold manufacturing.

• Transactions of Materials Processing
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• v.12 no.8
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• pp.702-709
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• 2003

In the automotive industry hydroforming of sheet metal pairs have received special attention because materials for various sheet metal components of vehicles have changed into the high strength steel, aluminum, and titanium blank having low formability. Uniform deformation over the whole region is a main advantage in the sheet hydroforming process. Because upper and lower parts could be produced simultaneously with one tool, hydroforming of sheet metal pairs is competitive in reducing the lead-time and development cost. In this paper, the multi-stage hydroforming process of sheet pair is proposed in order to increase the formability of a structural part like the oil pan shape. The upper die for forming oil pan shape is divided into two parts which can move separately. By the finite element simulation, the design parameters such as geometry of the tool and detailed specification of hydraulic pump were calculated and verified. For the strict comparison of the proposed process, the blank holding force is kept to a constant value during deformation by hydraulic valve. The deformed shape and strain distribution of the manufactured parts with the proposed process are compared with the results of simulation. In the multi-stage hydroforming process, maximum thickness strain was improved by more than 30 percent.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.601-606
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• 2009

High strength steels are widely used for lightweight automobile parts and the control of springback is very important in sheet metal forming. The object of this study is to develop the forming process for stair type side sill made of high strength steel, DP780. Stair type side sill with local formed area and geometry change area can improve stiffness and design freedom but there are few studies for forming process. The forming technology considered in this paper is form type process, which has many advantages for forming of high strength steel compared with draw type process. Finite element analysis is carried out to predict formability and springback. It is shown that angle calibration of die is essential for reducing springback, and local forming involving bead is effective to control springback also. The effectiveness of local forming and angle calibration is verified by experimental.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.10
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• pp.2653-2663
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• 1994

The design of sheet metal working processes is based on the knowledge about the deformation mechanism and the influence of the process parameters. The typical geometric process parameters are the die geometry, the initial sheet thickness, the initial blank shape, and so on. The initial blank shape is of vital importance in the most sheet metal forming operations, especially in the deep drawing process, since the forming load and the strain distribution are significantly affected by the shape of an initial blank. The influence of the initial blank shape on a square cup deep drawing process is investigated by the numerical simulation and the experiment. The numerical simulation is carried out by a modified membrane finite element method which takes bending deformation into account. The numerical and experi-mental results show that the initial blank shape have strong influence on the forming load and the strain distribution. The numerical results are compared with the experimental results and other numerical results which are calculated with the membrane theory.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.6
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• pp.88-96
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• 2006

The objective of this research works is to develop back panel dies of PDP TV with a large size. In order to design the geometry of the dies and an initial size of blank optimally, the finite element analysis has been carried out using AUTOFORM V4.2. The conner radius of the upper trimming area and the distance from the outer line of the blank holder to the outer line of the blank have been selected as design parameters to remove the wrinkling of the trimming area. The results of the analyses have been shown that a feasible product without wrinkles and skid lines can be obtained when the conner radius ranges from 6mm to 8mm and the distance lines in the range of 40-60mm. From the proposed design of the dies and an initial blank size, the final die set of the back panel has been successfully manufactured.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.12
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• pp.115-125
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• 2003

The design methodology of plastic injection molding die has been gradually moved from two-dimensional line drawings to three-dimensional solid models. The 3D design gives many benefits, a few of which are: ease of design change, data associativity from concept design to final assembly. In the paper represented is the implementation of a program which automatically generates 3D mold-bases and cooling-lines, conforming to given geometric constraints. It utilized a commercial CAD software and the related API(application program interface) libraries. We constructed a DB(database) of typical mold-bases assembled from standard parts, from which the geometry (position & dimension) of a mold-base and composed parts can be automatical]y determined by a few key parameters. Also we classified cooling lines into several typical types and constructed a DB, from which the position of cooling lines is automatically determined. The research is expected not only to simplify construction of a 3D mold-base model including cooling lines but also to reduce design efforts, by way of databases and automatized determination of geometric dimensions.

• Journal of Powder Materials
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• v.13 no.2 s.55
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• pp.124-128
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• 2006

In recent years, equal channel angular pressing (ECAP) has been the subject of intensive study due to its capability of producing fully dense samples having a ultrafine grain size. In this paper, the ECAP process was applied to metallic powders in order to achieve both powder consolidation and grain refinement. In the ECAP process for solid and powder metals, knowledge of the internal stress, strain and strain rate distribution is fundamental to the determination of the optimum process conditions for a given material. The properties of the ECAP processed solid and powder materials are strongly dependent on the shear plastic deformation behavior during ECAP, which is controlled mainly by die geometry, material properties, and process conditions. In this study, we investigated the consolidation, plastic deformation and microstructure evolution behaviour of the powder compact during ECAP.