• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.06a
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• pp.173-184
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• 1994

A method of obtaining deformation severity of axisymmetric shape deep-drawn products was developed. Strain states of products produced by single or multi-stage drawing were predicted by using finite element analysis. This method used minimization of potential energy between the known shape of final product and the unknown in initial blank. And that was done numerically by nonlinear finite element method. Deformation theory of plasticity was used for practical purposes. From predicted strain states of drawn parts, deformation severity was found by using forming limit diagrams.

• Transactions of Materials Processing
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• v.7 no.6
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• pp.575-585
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• 1998

An automated surface-strain measuring system using the image processing technique is developed in the present study which consists of the hardware to capture and to display digital images. and the software to calculate the 3-D informations of grid points from two views. New or improved algorithms for the mapping and establishing correspondence of grid points and elements the camera calibration and the subpixel measurement of grid points are implemented. As an application of the present system the surface-strains of deformed blanks in the limitting dome height test the square cup deep-drawing and punch stretching to obtain the forming limit diagram are measured. The results are com-pared with those obtained by conventional manual methods.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.1
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• pp.169-178
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• 1991

A plane-strain finite element analysis of sheet metal forming is carried out by using the rigid-plastic FEM based on the membrane theory. The sheet material is assumed to possess normal anisotropy and to obey Hill's new yield criterion and its associated flow rule. A formulation of initial guess generation for the displacement field is derived by using the nonlinear elastic FEM. A method of contact treatment is proposed in which the skew boundary condition for arbitrarily shaped tools is successively used during iteration. In order to verify the validity of the developed method, plane-strain drawing with tools in analytic expression and with arbitrarily shaped tools is analyzed and compared with the published results. The comparison shows that the present method can be effectively used in the analysis of plane-strain sheet metal forming and thus provides the basis of approximate sectional analysis of panel-like sheet forming.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.10
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• pp.40-49
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• 1995

This paper presents the performance and problems in analysis method and testing system of Electronic Speckle Pattern Interferometry (ESPI) method, in measuring two - dimensional in-plane displacement. The anyalysis result of measurement by ESPE is quite comparable to that tof measurement by strain gauge method. This implies that the method of ESPE is a very effective tool in non-contact two-dimensional in-plane strain analysis. But there is a controversal point, measurment error. This error is discussed to be affected not by ESPE method itself, but by its analysis scheme of the interference fringe, where the first-order interpolation has been applied to the points of strain measured. In this case, it is turned out that the more errors would be occurred in the large interval of fringe. And so this paper describes a computer method for drawing when the height is available only for some arbitrary collection of points. The method is based on a distance-weighted, last- squares approximation technique with the weight varying with the distance of the data points.

• Korean Journal of Metals and Materials
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• v.46 no.12
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• pp.780-787
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• 2008

For the advanced high strength steels (AHSS), high-manganese TWIP (twinning induced plasticity) steels exhibit high tensile strength (800-1000 MPa) and high elongation (50-60%). However, the TWIP steels need to be understood of delayed fracture following the cup drawing test. Among the factors to cause delayed fracture, i.e, martensite transformation, hydrogen embrittlement and residual stress, the effects of martensite transformation (${\gamma}{\rightarrow}{\varepsilon}$ or ${\gamma}{\rightarrow}{\alpha}^{\prime}$) were investigated on the delayed fracture phenomenon. Microstructural phase analysis was conducted for cold rolled (20, 60, 80% reduction ratio) steels and tensile deformed (20, 40, 60% strain) steels. For the Al-added TWIP steels, no martensite phase was found in the cold rolled and tensile deformed specimen. But, the TWIP steels with no Al addition indicated the martensite transformation. The cup drawing specimens showed the martensite transformation irrespective of the Al-addition to the TWIP steel. However, the TWIP steel with no Al exhibited the larger amount of martensite than the case of the TWIP steel with Al addition. For the reason, it was possible to conclude that the Al addition suppressed the martensite transformation in TWIP steels, therefore preventing the delayed fracture effectively. However, it was interesting to note that the mechanism of delayed fracture should be incorporated with hydrogen embrittlement and/or residual stress as well as the martensite transformation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.7
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• pp.2246-2256
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• 1996

To investigate the effect of material and precess variables on stamping formability of sheet materials, simulations for the cup drawing and the Yoshida buckling test were carried out using ABAQUS, commercial nonlinear finite element analysis code. The various factor effects on stamping formability of sheet materials were analyzed by the designed process according to Taguch's orthogonal array experiment. Cup drawing simulation showed that local neckling was very sensitive to plastic anisotropy parameter of sheet material and friction coefficient between sheet and tool interface. Simulations for the Yoshida buckling test have clarified that buckling behaviour of sheet material was mostly susceptible to yield stress and sheet thickness mostly. However, plastic anisotropy parameter and strain hardening coefficient affect moderately buckling behaviour of steel sheets after the buckling initiation.

• Transactions of Materials Processing
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• v.23 no.4
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• pp.238-243
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• 2014

Recently, magnesium alloys have been widely used in the automotive, aerospace and electronics industries with the advantages of high specific strength, excellent machinability, high electrical conductivity, and high thermal conductivity. Deep drawn magnesium alloys not only meet the demands environmentally and the need for lighter products, but also can lead to remarkably improved productivity and more rapid qualification of the product The current study reports on a failure prediction procedure using finite element modeling (FEM) and a ductile fracture criterion and applies this procedure to the design of a deep drawing process. Critical damage values were determined from a series of uniaxial tensile tests and FEM simulations. They were then expressed as a function of strain rate and temperature. Based on the plastic deformation histories obtained from the FEM analyses of the warm drawing process and the critical damage value curves, the initiation time and location of fracture were predicted. The proposed method was applied to the process design for fabrication of a Mg automotive compressor case and verified with experimental results. The final results indicate that a Mg case part 39% lighter than an Al die casting part can be produced without any defects.

• Transactions of Materials Processing
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• v.15 no.3 s.84
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• pp.232-240
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• 2006

Magnesium alloys are expected to be widely used fur the parts of structural and electronic appliances due to their lightweight and EMI shielding characteristics. While the die casting has been mainly used to manufacture the parts from the magnesium alloys, the press forming is considered as an alternative to the die casting for saving the manufacturing cost and improving the structural strength of the magnesium alloy parts. However, the magnesium alloy has low formability at room temperature and therefore, in many cases, forming at elevated temperatures is necessary to obtain the required material flow without failure. In the present study, square cup deep drawing tests using the magnesium alloy AZ31 sheet were experimentally conducted at various elevated temperatures as well as room temperature, and the corresponding finite-element simulations, which calculated the damage evolution based on the Oyane's criterion, were conducted using the stress-strain relations from the tensile tests at various temperatures. The formability predictability by the finite-element analysis was investigated by comparing the predicted damage distributions over the deformed AZ31 sheet at elevated temperatures with the corresponding experimental deformations with failures.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.590-595
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• 2007

This paper introduces a new approach to take account of bending history in finite element inverse analysis during sheet metal forming process. A modified membrane element was adopted for finite element inverse analysis so that bending-unbending energy was additionally imposed in the total plastic energy, predicting bending-unbending regions using the geometry of the final shape and tools. An algorithm was applied to a cylindrical cup deep drawing process. The blank shape and the distribution of the thickness strain were compared with those obtained from the incremental finite element analysis in order to evaluate the effect of the bending history. The algorithm reduced the difference between the results of the inverse analysis from those of the incremental analysis due to bending history. The analysis was also carried out with the variation of the thickness of the initial blank to investigate the effect of bending deformation. The results showed that the difference was remarkably reduced as the thickness of the initial blank increased. This indicates that the finite element inverse analysis cooperated with the suggested scheme is useful to obtain more accurate results, especially when bending effects are significant.

• International Journal of Advanced Culture Technology
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• v.3 no.1
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• pp.68-77
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• 2015

This study was the use of the finite element method in the deep drawing process of a rectangular shell cup. The aim was to analyse the equivalent strain in the workpiece and to find out what happened to the disc blank sheet before the forming by stamping. The rectangular shell cup was $24{\times}30{\times}20$ mm. and made of 2mm.thick SUS 403 and SUS 304 stainless steel. There were 3 types of blank sheets: 1) square sheet 2) 45 degree angled edge cutting sheet 3) circular sheet. It was found out that the drawing up with the use of 3 types of blank sheet made of SUS 304 stainless steel had no risk in the workpiece. For the stamping of the rectangular shell that used a square sheet made of SUS 403 stainless steel, it was found out that there was no risk in the work piece, but with the use of 45 degree angled edge cutting sheet or round sheet, the work piece had a risk to be damaged.