• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1989년도 한국자동제어학술회의논문집; Seoul, Korea; 27-28 Oct. 1989
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• pp.302-307
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• 1989

A pressure tracking control of hydroforming process is considered in this paper. To account for nonlinearities and uncertainties of the process, an iterative learning control scheme is proposed using Cerebellar Model Arithmatic Computer (CMAC). The experimental result shows that the proposed learning control is superior to any fixed gain controller in the sense that it enables the system to do the same work more effectively as the number of operation increases.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1990년도 한국자동제어학술회의논문집(국내학술편); KOEX, Seoul; 26-27 Oct. 1990
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• pp.350-355
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• 1990

A pressure tracking of hydroforming process is considered in this paper. To account for nonlinearities and uncertainty of the process. A fuzzy SOC based iterative learning control algorithm is proposed. A series of experimentals were performed for the pressure tracking control of the process. The experimental results show that regardless of inherent nonlinearties and uncertainties associated with hydraulic system. A good pressure tracking control performance is obtained using the proposed fuzzy learning control algorithm.

• 한국자동차공학회논문집
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• 제17권2호
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• pp.98-103
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• 2009

The environment and energy related problem has become one of the most important global issues in recent years. One of the most effective ways of improving the fuel efficiency of automobiles is the weight reduction. In order to obtain this goal the hydroforming technology has been adapting for the high strength steel and its application is being widened. In present study, the chassis components (mainly cross members of engine cradle) simulation and development by hydroforming technology to apply high strength steel having tensile strength of 440 MPa grade is studied. In the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydroformability in details. Overall possibility of hydroformable chassis 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, performing and hydroforming. In the die design stage, all the components of prototyping tool were designed and interference with press was investigated from the point of geometry and thinning.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.247-250
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• 2005

The need for improved fuel efficiency, weight reduction has motivated the automotive industry to focus on aluminum alloys as a replacement for steel-based alloy. To cope with the needs for high structural rigidity with low weight, it is forecasted that substantial amount of cast components will be replaced by tubular parts which are mainly manufactured by the extruded aluminum tubes. The extrusion process is utilized to produce tubes and hollow sections. Because there is no weld seam, the circumferential mechanical properties may be uniform and advantageous for hydroforming. However the possibility of the occurrence of a surface defect is very high, especially due to the temperature increase from forming at high pressure when it comes out of the bearing and the roughness of the bearing, which cause the surface defects such as the dies line and pick-up. And when forming a extruded aluminum tube, the free surface of the tube becomes rough with increasing plastic strain. This is well known as orange peel phenomena and has a great effect not only on the surface quality of a product but also on the forming limit. In an attempt to increase the forming limit of the tubular specimen, in the present paper, surface asperities generated during the hydroforming process are polished to eliminate the weak positions of the tube which lead to a localized necking. It is shown that the forming limit of the tube can be considerably improved by simple method of polishing the surface roughness during hydroforming. And also the extent of the crack propagation caused by dies lines generated during the extrusion process is evaluated according to the deformed shape of the tube.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.254-257
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• 2007

In this study, hydroformability and mechanical properties of pre- and post- heat treated Al6061 tubes at different extrusion type were investigated. For the investigation, as-extruded, full annealed and T6-treated Al 6061 tubes at different extrusion type were prepared. To evaluate the hydroformability, uni-axial tensile test and free bulge test were performed at room temperature and $200^{\circ}C$. Also mechanical properties of hydroformed part at various pre- and post-heat treatments were estimated by tensile test. And the tensile test specimens were obtained from hexagonal prototype hydroformed tube at $200^{\circ}C$. As for the heat treatment, hydroformability of full annealed tube is 25% higher than that of extruded tube. The tensile strength and elongation were more than 330MPa and 12%, respectively, when hydroformed part was post-T6 treated after hydroforming of pre- full annealed tube. However, hydroformed part using T6 pre treated tube represents high strength and low elongation, 8%. Therefore, the T6 treatment after hydroforming for as-extruded tube is cost-effective. Hydroformability of Al6061 tube showed similar value for both extrusion types. But flow stress of seam tube showed $20{\sim}50MPa$ lower value.

• 소성∙가공
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• 제14권9호통권81호
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• pp.756-763
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• 2005

The applicability and productivity of hydroforming process can be increased by combining pre- and post-forming processes such as the bending, piercing and embedding process. For the fabrication of automotive parts, the hollow bodies with connecting nuts are widely used to connect parts together. Hollow body with connecting nuts has been conventionally fabricated by welding nuts or screwing in autobody screws. It requires multiple steps and devices fur the welding and/or screwing Therefore in this study, hydro-embedding process that combines the hydraulic embedding of connecting element(nut) with hydroforming process is investigated. Studies on the hydro-embedding technology have been performed to optimize the shape of the connecting element by analyzing the deformed mode of the embedded tube The effects of the shape of the screw tip, screw thread and shape of thread on the connection force between the tube and the connecting element have been investigated to optimize the shape of connecting element. Finite element analysis has also been performed to provide deformation behaviors of the tube surrounding a hole produced by hydro-embedding.

• 제어로봇시스템학회논문지
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• 제6권3호
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• pp.329-337
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• 2000

This study describes a pressure tracking control of hydroforming process which is used for precision forming of sheet metals. The hydroforming operation is performed in the high-pressure chamber strictly controlled by pressure control valve and by the upward motion of a punch moving at a constant speed, The pressure tracking control is very difficult to design and often does not guarantee satisfactory performances be-cause of the punch motion and the nonlinearities and uncertainties of the hydraulic components. To account for these nonlinearities and uncertainties of the process and iterative learning controller is proposed using Cerebellar Model Arithmetic Computer (CMAC). The experimental results show that the proposed learning control is superior to any fixed gain controller in the sense that it enables the system to do the same work more effectively as the number of operation increases. In addition reardless of the uncertainties and nonlinearities of the form-ing process dynamics it can be effectively applied with little a priori knowledge abuot the process.

• 열처리공학회지
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• 제18권3호
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• pp.172-176
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• 2005

Modern automobiles are built with a steadily increasing variety of materials and semifinished products. The traditional composition of steel sheet and cast iron is being replaced with other materials such as aluminum and magnesium. But low formability of these materials has prevented the application of the automotive components. The formability can be enhanced by conducting the warm hydroforming using induction heating device which can raise the temperature of the specimen very quickly. The specimen applied to the test is A6061, A7075 extruded tubes which belong to the age-hardenable aluminum alloys. But in the case of A6061 age hardening occurs at room temperature or at elevated temperatures before and after the forming process. In this study the effects of the heating condition such as heating time, preset temperature, holding time during die closing and forming time on the hydroformability are analyzed to evaluate the phenomena such as dynamic strain hardening and ageing hardening at high temperatures after the hydroforming process.

• 소성∙가공
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• 제18권4호
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• pp.336-341
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• 2009

Hydroformed parts have higher dimensional accuracy, structural strength, and dimensional repeatability. Particularly in the automotive industry, manufacturing of parts with complex shapes from tubular materials sometimes requires one or more pre-forming operations such as bending before the hydroforming process. The pre-bending process is an important process for the successful hydroforming in the case where the perimeter of the blank is nearly the same as that of final product. The bendability of a tube depends on the parameters such as the bending radius, welding methods, mechanical properties and hardness. Through the stainless steel tubes bent by rotary draw bending machine, this study shows the following : (1) The influence on spring back ratio variation with stress level in the welded bent tube. (2) The Cross-section ovality variation with weld seam position and bending radius. (3) The relation between elongation and thickness reduction of tension zone with weld seam position and bending radius. (4) Workability evaluation of bent stainless steel tubes through the hardness of materials and hardness increment. The results of this study may help to understanding of characteristics on bendability of stainless steel tubes.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 추계학술대회 논문집
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• pp.132-135
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• 2007

In this study, hydroformability and mechanical properties of pre- and post- heat treated Al6061 tubes at different extrusion type were investigated. For the investigation, as-extruded, full annealed and T6-treated Al6061 tubes at different extrusion type were prepared. To evaluate the hydroformability, uni-axial tensile test and free bulge test were performed at room temperature and $250^{\circ}C$. Also mechanical properties of hydroformed part at various pre- and post-heat treatments were estimated by tensile test. And the tensile test specimens were obtained from hexagonal prototype hydroformed tube at $250^{\circ}C$. As for the heat treatment, hydroformability of full annealed tube is 25% higher than that of extruded tube. The tensile strength and elongation were more than 330MPa and 12%, respectively, when hydroformed part was post-T6 treated after hydroforming of pre- full annealed tube. However, hydroformed part using T6 pre treated tube represents high strength and low elongation, 8%. Therefore, the T6 treatment after hydroforming for as-extruded tube is cost-effective. Hydroformability of Al6061 tube showed similar value for both extrusion types. But flow stress of seam tube showed $20{\sim}50MPa$ lower value.