• 한국생산제조학회지
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• 제26권4호
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• pp.410-417
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• 2017

Hydro-forming is being employed increasingly to realize lightweight vehicular parts. The bumper beam produced by this process weighs 30% less than the conventional products with equal stiffness. However, hydro-forming involves complex parameters to obtain the target geometry and low residual stress. Parametric studies are conducted using finite element analysis to obtain optimized process conditions. Through these numerical approaches, the internal and holding pressures and feeder forward stroke along the extruded direction are optimized to achieve low residual stress and to minimize springback. The numerical results are verified by experimental observations made by employing a three-dimensional laser scanner. The numerical and experimental results are compared in terms of the springback. Both results show similar tendencies.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 춘계학술대회 논문집
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• pp.110-114
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• 2001

The welding pressure in porthole die extrusion is affected by the shape of welding chamber. It is very important to increase the welding pressure when the tube is used particulary as the materials of hydroforming processing. The high circumferential stress of the tube would make the welding pressure increase during the porthole die extrusion. In order to increase the circumferential stress, it is necessary to make the billets pass through the narrow gap between the conical die and the conical mandrel. This paper describes the welding pressure by the experiments with the two types of the chamber. One of them is the chamber between the flat die and straight mandrel, and the other one is the chamber between the conical die and conical mandrel. The result of the experiments show that the conical chamber makes the welding pressure increase by the effect of the reducing the diameteres of tube.

• Structural Engineering and Mechanics
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• 제50권4호
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• pp.563-573
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• 2014

In hydroforming, the general technique employed to overcome the problem of die corner filling consist in increasing the maximum fluid pressure during the forming process. This technique, in other hand, leads to other difficulties such as thinning and rupturing of the final work piece. In this paper, a new technique has been suggested in order to produce a part with complete filled corners. In this approach, two moveable bushes have been used. So, the workpiece moves driven by both bushes simultaneously. In the first stage, system pressure increases until a maximum of 15 MPa, providing aninitial tube bulge. The results showed that the pressure in this stage have to be limited to 17 MPa to avoid fracture. In a second stage, bushes are moved keeping the constant initial pressure. The punches act simultaneously at the die extremities. Results show that the friction between part and die decreases during the forming process significantly. Also, by using this technique it is possible to produce a part with reasonable uniform thickness distribution. Other outcomes of applying this method are the lower pressures required to manufacture a workpiece with complete filled corners with no wrinkling.

• Journal of Welding and Joining
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• 제22권6호
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• pp.19-24
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• 2004

The laser welding and its analysis of thin-sheet carbon steels were carried out with high power $CO_{2}$ laser. The main factor of weld quality of laser welding is gap and edge quality. This work was preformed to focus on the gap tolerance problem during laser welding. First, bead on plate welding of thin sheet was examined to investigate the effect of laser welding variables, and to obtain optimum welding condition. Butt welding was also carried out to show the effect of gap on the laser weldability of thin sheet. In order to investigate the effect of gap on formability of welded thin sheet, LDH test was caried out. At high welding speed, the partial penetration was obtained by low heat input. Otherwise, porosity was formed in the bead at low weld speed because of too much heat input. The optimum welding condition of welding was derived from bead width, penetration and hardness property. The maximum gap tolerance on laser welding was observed to be about 0.2mm. This gap size has good relationship with beam size of laser spot(about 0.3mm). The formability of welded sheet was about $80{\%}$ value of base metal and the gap size has not affected on the formability, although weld quality is dependent on the gap size.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.239-242
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• 2005

In the roll forming, a flat strip is progressively deformed by feeding it through a series of rotating rolls. There are various layouts for the tube toll-forming stages. The process sequences are as follows: leveling, roll-forming, welding, bead removing, seam annealing, cooling, sizing and cutting. Electric resistance welded(ERW) tubes have been widely used for the machinery parts, especially for hydroformed automotive parts. However conventional ERW tubes do not have a high formability because of hardening of welded portion by rapid cooling. Moreover the decrease in thickness of the welded portion during the grinding of the inner and outer bead may reduce the formability of the tube. In case of applying the tubular parts without grinding the bead, the flow of the fluid can be prevented due to the turbulent flow induced by the inner bead. In attempt to determine the optimal bead grinding amount in the roll forming process, in the present paper, the effects of the removal depth and width of the inner beads on the hydroformability are analyzed by the finite element simulation.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.503-506
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• 2008

본 연구에서는 하이드로포밍 공정을 적용한 엔진크레들 제품에 대해 최종 제품의 강도를 평가하고자 하였다. 먼저 적용 판재인 370과 440 소재에 대해 인장시험을 수행하여 소재의 경도와 강도의 상관관계를 분석하여 경도와 강도의 변환식을 도출하였다. 그런 다음 예비굽힘, 예비성형, 최종성형된 제품의 각 공정에 따른 유효변형률을 측정하고 같은 위치에서의 경도를 측정하였다. 측정된 경도는 앞서 도출한 경도와 강도의 변환식에 대입하여 각 공정을 마친 제품의 강도를 예측하고 결국 하이드로포밍된 엔진 크레들 제품의 유효변형률에 따른 강도를 예측식을 실험으로 도출하였다. 그 결과 예비굽힘, 예비성형, 최종성형을 마친 엔진 크레들 제품에 대해 유효변형률이 $24{\sim}72%$로 변하였고 이때 HF370의 경우에는 유동응력값이 $375{\sim}500MPa$로 증가하여 원소재에 비해 성형 후 $25{\sim}66%$의 강도증가량을 보였고, HF440의 경우에는 $470{\sim}565MPa$로 증가하여, 원소재에 비해 $17{\sim}41%$로 강도가 증가하는 것으로 나타났다. 그리고 이와 같은 변화값을 이용하여 유효변형률과 강도의 상관관계를 도출하였다.

• 한국자동차공학회논문집
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• 제16권1호
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• pp.86-92
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• 2008

Recently, the use of tubes in the manufacturing of the automobile parts has increased and therefore many automotive manufactures have tried to use hydro-forming technology. The hydro-forming technology may cause many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower spring-back, improved strength and durability and design flexibility. In this study, the whole process of front engine cradle (or front sub-frame) parts development by tube hydro-forming using steel material having tensile strength of 440MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydro-formability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape on automotive sub-frame by hydro-forming process were carefully investigated. Overall possibility of hydro-formable sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydro-forming. At the die design stage, all the components of prototyping tools are designed and interference with press is examined from the point of geometry and thinning.