• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.63-70
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• 2016

Deep drawing is a forming process in which a blank of sheet metal is radially drawn into a forming die by the mechanical action of a punch and converted to required shape. Deep drawing involves complex material flow conditions and force distributions. Radial drawing stresses and tangential compressive stresses are induced in flange region due to the material retention property. These compressive stresses result in wrinkling phenomenon in flange region. Normally blank holder is applied for restricting wrinkles. Tensile stresses in radial direction initiate thinning in the wall region of cup. The thinning results into cracking or fracture. The finite element method is widely applied worldwide to simulate the deep drawing process. For real-life simulations of deep drawing process an accurate numerical model, as well as an accurate description of material behavior and contact conditions, is necessary. The finite element method is a powerful tool to predict material thinning deformations before prototypes are made. The proposed innovative methodology combines two techniques for prediction and optimization of thinning in automotive sealing cover. Taguchi design of experiments and analysis of variance has been applied to analyze the influencing process parameters on Thinning. Mathematical relations have been developed to correlate input process parameters and Thinning. Optimization problem has been formulated for thinning and Genetic Algorithm has been applied for optimization. Experimental validation of results proves the applicability of newly proposed approach. The optimized component when manufactured is observed to be safe, no thinning or fracture is observed.

• Journal of Advanced Marine Engineering and Technology
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• v.33 no.4
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• pp.509-516
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• 2009

This paper is the study on improving the coefficient of utilization of material in deep drawing process. Cylindrical cup drawing process is widely used in sheet metal forming process. The blank shape is one of the important things in sheet metal forming process. It is produced for the bridge of blank in a blanking process. The coefficient of utilization of material is much effected by this bridge of blank. This study offered a new process method to reduce the loss of material. The new blank shape offered and manufactured by new process method is investigated by a finite element method and the experiment. Then the wrinkling, the punch load, the thickness distribution is observed. This result is different from the result of circular blank process. And it is got that the Max strain, the wrinkle and the height of the wrinkle are effected by the holding force and the punch load. As a result, if the processing optimum condition is found, the loss of material will be reduced. It is necessary to research systematically about determining the optimum value of process variables.

• International Journal of Precision Engineering and Manufacturing
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• v.9 no.3
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• pp.55-58
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• 2008

Hydroforming is a forming technology in which a steel tube is set in a die and formed to fit a specified shape by applying hydraulic pressure from inside the tube while also applying force in the tube axial direction (axial feed). In present study, the entire design process chain for an automotive cross-member was simulated and developed using hydroforming technology on high-strength steel. The part design stage required a feasibility study. The process was designed using computer-aided design techniques to confirm the actual hydroformability of the part in detail. The possibility of using hydroformable cross-member parts was examined using cross-sectional analyses, which were essential to ensure the formability of the tube material for each forming step, including pre-bending and hydroforming. The die design stage included all the components of a prototyping tool. Press interference was investigated in terms of geometry and thinning.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.123-128
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• 2000

Fundamental and informative data of axi-symmetric stretch-drawing of several sheetmetals with thicknesses of 0.7-1.0mm are presented both for single and double operations. Very small radius is applied to the die profile (or-shoulder) ion all operations. to induce wall-thinning by the effect of bending-under-tension from which the name 'stretch-drawing' comes. It is clearly demonstrated that deeper cups could be formed by single and double stretch-drawings from smaller circular blanks due to such wall-thinning action than in the usual deep-drawing of larger blanks, From this fact it is emphasized that the deep-drawability of a sheet metal is not evaluated simply by the conventional L.D.R (limiting drawing ratio) but the depth of the drawn cup should also be taken into account./ Many experimental data about various metals and thicknesses given in this paper offer a valuable information in this process for more general use which recommends to replace the conventional deep-drawing process by the stretch-drawing process both for single and double operations. In the single stretch-drawing it is also confirmed that a deeper cup can be produced by raising the blank-holding force at later stage of operation.

• Tribology and Lubricants
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• v.4 no.1
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• pp.56-68
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• 1988

The wear resistance of P-bronze which is widely used as worm gear material was investigated. In order 1o study the effect of additional elements on the wear resistance of Pbronze, the applied load and sliding time were selected as variables, and SCM4, were used as against metal. The addition of Fe improve wear resistance, for it precipities hard Fe$_3$ P phase and the work hardening coefficients are lowered due to decreasing solubility of P. When Fe is added in conventional P-bronze, the alloy is rather sliding than forming wear debris by frictional force during wear test. Experimental results indicated that the wear mechanisms for P-bronze are mainly consisted of abrasive wear due to Beilby layer forming mechanism and adhesive wear due to thermally activated wear mechanism. Moreover, the weight loss is decreased in accordance with increasing load and time. However the rate of wear loss is decreased as the sliding time is increased.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.2
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• pp.177-185
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• 2001

This study shows the process design and forming analysis of permalloy shielding can that support the automobile multi-display parts to indicate the accurate information of car. This study is particularly important, since the strain and thickness of permalloy shielding can is known to affect the magnetic properties such as coercivity and permeability quite thickness of permalloy shielding can is known to affect the magnetic properties such as coercivity and permeability quite sensitively. The objective functions are strain and thickness deviation. The punch radius, die radius and blank holding force are considered as design parameters. Orthogonal array (OA) table and characteristics are applied to neural network (NN) as train data. After training, the optimal and robust condition of design parameters is selected. This study shows the correlation between the design methodology of NN and the statistical design of experiments (DOE) approach.

• Transactions of Materials Processing
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• v.18 no.1
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• pp.67-72
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• 2009

This paper covers finite element simulations to evaluate tube bending process of auto chassis component i.e. trailing-arm product. The rear of the auto chassis structure is primarily composed of CTBA and trailing-arm. When a car rolls into a corner, the trailing arm reacts to roll in the same degree as the car body. During the bending process of trailing arm the tube undergoes significant deformation. Thus forming defects such as excessive thinning and flattening of the tube will be formed in the outside of the tube. In this paper, we analyzed the effect of process parameters in rotary draw bending process and searched the optimized combination of process parameters using orthogonal arrays method to minimize the forming defects. In this process we analyzed several parameters which are displacement of pressure die, boosting force, initial position of mandrel bar, dimensions of mandrel in regarding to the thinning and flattening of the tube.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.6
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• pp.81-86
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• 2017

The high-pressure resin transfer molding (HP-RTM) process has a very effective for the mass production of carbon fiber reinforced plastic (CFRP) for light weight in the automotive industry. In developing robust equipment, new process and fast cure matrix systems reduces significantly the cycle time less than 5 minutes in recent years. This paper describes the cavity pressure, temperature and molding characteristics of the HP-RTM process. The HP-RTM mold was equipped with two cavity pressure sensors and three temperature sensors. The cavity pressure characteristics of the HP-RTM injection, pressurization, and curing processes were studied. This experiment was conducted with selected process parameters such as mold cap size, maximum press force, and injection volume. Consequently, this monitoring method provides correlations between the selected process parameters and final forming characteristics in this work.

• Design & Manufacturing
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• v.15 no.4
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• pp.51-56
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• 2021

Piercing is the process of shearing a circular hole in sheet metal, whose high shear force makes it difficult to secure the durability of tools. In addition, uneven clearance between tools due to poor alignment of the piercing punch causes accelerated die wear and breakage of the tool. This study reviewed the feasibility of in-situ determining alignment failure during the piercing process by analyzing the signal deviation of a bolt-type piezo sensor installed inside the tool whose alignment level was controlled. Finite element analysis was performed to select the optimal sensor location on the piercing tool for sensitive detection of process signals. A well-aligned piercing process results in uniform deformation in the circumferential direction, and shearing is completed at a stroke similar to the sheet thickness. Afterward, a sharp decrease in shear load is observed. The misaligned piecing punch leads to a gradual decrease in the load after the maximum shear load. This gradual decrease is due to the progressive shear deformation that proceeds in the circumferential direction after the initial crack occurs at the narrow clearance site. Therefore, analyzing the stroke at which the maximum shear load occurs and the load reduction rate after that could detect the misalignment of the piercing punch in real-time.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.7
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• pp.3135-3141
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• 2013

This study derives the optimal conditions for design parameters of clinch stud with high torque resistance and bonding force by using FE simulation and Taguchi method. Maximum forming load and filled rate of material are considered as objective functions. Height and depth of groove with diameter and depth of lobe are chosen as design parameters. These control factors and the friction considered as noise factor are combined by orthogonal array. Forming load and filled rate are evaluated through the simulation. Simulation results are analyzed by using the ratio of signal to noise through Taguchi method. From these results, their optimal combination conditions are proposed. In the order of the most important parameter which affects filled rate, there are the height of lobe, the height of groove, the radius of lobe and the depth of groove.