• Transactions of Materials Processing
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• v.21 no.6
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• pp.384-388
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• 2012

Sheet metal forming processes induce residual stress in the final product due to plastic deformation. The residual stress leads to elastic recovery of the formed part called springback, which causes shape errors in the final product. This error is a serious issue, especially for high strength steels, which are widely used in auto-body structures. Therefore, the evaluation of the amount of springback becomes critical for high strength steels. This paper investigates the springback behavior of DP780 steel sheets after the U-bending process using the geometry of the standard U-shape tool from the NUMISHEET'93 benchmark problem. The amounts of springback were measured as a function of the intrusion direction, forming speed and blank holding force.

• Laser Solutions
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• v.7 no.2
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• pp.1-10
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• 2004

This work was attempted to join SCP sheet and STS304 sheet by using Nd:YAC laser beam. SCP sheet has good formability and low cost, while STS304 has excellent corrosion resistance and mechanical properties in high temp. In this experiment, butt joint type was used to develop the tailored blank welding for dissimilar steel. Sheets which have different thermal properties. Computer simulation was conducted to obtain the off-set position for efficient welding by considering laser power, scanning speed, focal length and basic properties. The result showed that the optimum thermal distribution was obtained when the laser beam was irradiated at $0.05{\sim}0.1$ mm off-set toward the SCP sheet side. The experiment was conducted based on the result of computer simulation to show the same optimum conditions. Optimum conditions were 3KW in laser beam power, 6m/min in scanning speed, -0.5mm in focal position, 0.1mm off-set toward SCP. Microhardness test, tensile test, bulge test, optical microscopy, EDS, and XRD were performed to observe the microstructure around fusion zone and to evaluate the mechanical properties of optimum conditions, The weld zone had high microhardness values by the formation of the martensitic structure. Tensile test measured the strength of welded region by vertical to strain direction and the elongation of welded region by parallel to strain direction. Bulge test showed $52\%$ formability of the original materials. Bead shape, grain size, and martensitic structure were observed by the optical microscopy in the weld zone. Detailed results of EDS, XRD confirmed that the welded region was connected of martensitic structure.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.1
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• pp.42-49
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• 2016

This study was analyed V-bending in order to analyze the spring-back phenomenon in the roll forming process. The material of forming sheet used in the roll forming process is high tension steel and the product name of sheet material is POSTEN 60. The most important variable is the number of roll passes (3-Pass, 4-Pass, 5-Pass, 6-Pass and 10-Pass) and other roll forming process variables were fixed. To determine the characteristics of the tension and compression, the forming sheet was analyzed by dividing the layer (Upper and Bottom) in the thickness direction from the center line. The results of FEM simulation analysis was derived to von-mises stress equivalent strain, and the spring-back value was calculated according to the final forming shape. The more number of the roll pass, von-mises stress and equivalent strain value of forming sheet were lowed. Also, spring-back values tended to decrease. The results of this study can be utilized for prediction and trend of spring-back value in the roll forming process applied to high tension steel sheet. So, development time and cost of the roll forming process is expected to be reduced.

• Journal of the Korean Society for Heat Treatment
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• v.11 no.3
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• pp.216-226
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• 1998

Heat treatment conditions and the formation of microstructures were studied for improving the transformation-induced plasticity(TRIP) effect of retained austenite and mechanical properties of Fe-0.2%C-1.5%Si-1.5%Mn sheet steel. An excellent combination of elongation about 30% and high strength over 760MPa was achieved by processing of intercritical annealing and isothermal holding Intercritical annealing the sheet steel produced fine particles($1{\sim}2{\mu}m$) of retained austenite which were stabilized due to C enrichment by subsequent holding in bainite transformation range. Heat treatment conditions were depended on the shape and distribution of second phases as well as the volume fraction and stability of retained austenrte. In this work, the heat treatment condition of optimal strength-elongation balance was obtained by holding the steel at $400^{\circ}C$ for 200sec, after intercritical annealing at $790^{\circ}C$ for 300sec.

• Transactions of the Korean Society of Automotive Engineers
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• v.2 no.1
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• pp.73-83
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• 1994

Press formabilities of aluminum sheets for automobile body were investigated. Plane strain stretching test (called RIST-PSST), cupping test and U bending test were performed to assess the press formability of aluminum sheets respectively. The results showed that aluminum sheets are generally inferior to cold-rolled steel sheet of deep drawing quality (CSP3N) in press formability. The limiting punch height (LPH) and limiting plane strain (FLCo) of aluminum sheets are 50%-70% level compared to that of CSP3N. Moreover, the limiting drawing ratios(LDR) of aluminum sheets are ranged between 1.95 and 2.1. The poor press formability of aluminum sheets is responsible for low values of total elongation and plastic anisotropy parameter in tensile characteristic. The shape fixability of aluminum sheets evaluated in U bending test is very poor due to its low elastic modulus compared to CSP3N.

• Transactions of Materials Processing
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• v.21 no.3
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• pp.186-194
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• 2012

Hot stamping is a forming method that offers various advantages such as superior mechanical properties, good formability, and very small springback. However, relatively large-sized parts, such as front pillars, exhibit poor formability when hot stamped due to the limited material flow and thickness reduction imparted by the process. This reduction in thickness can also lead to cracks. One of the reasons is the relatively high friction between the sheet and the die. In this study, in order to obtain the optimal conditions for hot stamping of front pillars, various process parameters were studied and analyzed using the sheet forming software, J-STAMP. The effects of various parameters such as the die structure, blank shape, blank holding force, punch speed, clearance(upper and lower dies) and distance block were analyzed and compared.

• Transactions of Materials Processing
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• v.18 no.6
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• pp.488-493
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• 2009

The very big springback of advanced high strength steel(AHSS) sheets invokes undesired shape defects, which can be generally eliminated by die correction or process parameter control. The springback reduction by controlling the forming process parameters is easy for the application, but limited for the bulky achievement. In this study, the effective die correction method, which obtains the modification of tool shape from the relationship between die design variable and springback, is introduced and is applied to the TWB tool of automotive side rail to show the validity and usefulness. Among the die correction trials repeatedly performed, the first trial is carried out by correcting the tool shape to the opposite direction to the springbacks of several tool sections. Next trials are done by extrapolating the springbacks of among the original tool uncorrected and the tools corrected negative amounts of the springback and by finding tool shapes without springbacks. After the angle of side wall and radius of curvature of horizontal bottom floor are chosen as design variables in the tool design of side rail, the tool shape is corrected 3 times. The accuracy of final shape within the assembly limit of 1mm and the springback reduction of 75.8% compared to the uncorrected tool are achieved.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.229-232
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• 2003

In the roll forming process, a sheet or strip of metal is continuously and progressively formed into a desired cross-sectional profile by feeding it through a series of forming roll. Accordingly, it is important to maintain the material properties of the initial sheet and deform uniformly during the roll forming. The roll forming process was estimated in consideration of some factors such as material properties, strip thickness, roll diameter, roll velocity, and the deformation of the material that influence the forming length. The hydroforming technology has been recognized as a new technique in manufacturing industry, especially in automotive industry. The formed pipe in used in hydroforming process is manufactured by the roll forming. The formability during hydroforming is very sensitive to the state of pipes which are made by roll forming. Particularly the amount of hardening during roll forming affects the formability. Therefore, it is necessary to design the optimum roll flower to reduce the local hardening. In this paper, optimum roll flower which has uniform strain distribution through sheet width was obtained by comparing strain distribution in various roll flower. Finite element analysis(FEA) is performed to estimate the strain distribution related to hardening by roll forming. A numerical analysis is carried out by SHAPE-RF.

• Steel and Composite Structures
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• v.33 no.5
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• pp.717-727
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• 2019

This paper is motivated by the lack of studies in the technical literature concerning to vibration analysis of a single-layered graphene sheet (SLGS) with corner cutout based on the nonlocal elasticity model framework of classical Kirchhoff thin plate. An isogeometric analysis (IGA) based upon non-uniform rational B-spline (NURBS) is employed for approximation of the L-shape SLGS deflection field. Trimming technique is employed to create the cutout in geometry of L-shape plate. The L-shape plate is assumed to be Free (F) in the straight edges of cutout while any arbitrary boundary conditions are applied to the other four straight edges including Simply supported (S), Clamped (C) and Free (F). The Numerical studies are carried out to express the influences of the nonlocal parameter, cutout dimensions, boundary conditions and mode numbers on the variations of the natural frequencies of SLGS. It is precisely shown that these parameters have considerable effects on the free vibration behavior of the system. In addition, numerical results are validated and compared with those achieved using other analysis, where an excellent agreement is found. The effectiveness and the accuracy of the present IGA approach have been demonstrated and it is shown that the IGA is efficient, robust and accurate in terms of nanoplate problems. This study serves as a benchmark for assessing the validity of numerical methods used to analyze the single-layered graphene sheet with corner cutout.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.3
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• pp.314-319
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• 2015

Invar is a compound metal of Fe-Ni system contained 36.5% Ni. The characteristic of invar is that the coefficient of thermal expansion is $1.0{\times}10^{-6}cm/^{\circ}C$. It is approximately 10 times smaller than series of steel. Because of this low thermal expansion characteristic of Invar, it is used to shadow mask of display device such as UHDTV or OLED TV. In this study, pulse current from pulse generator instead of DC current is used to overcome the disadvantages of the conventional electrochemical machining. Pulsed current with different duty factor in PECM affect the precise geometry. Pulse electrochemical machining is conducted to machine the micro hole to the invar sheet with different duty factor. The machined shape and overcut of invar sheet with different duty factor is observed by optical microscope and scanning electron microscope (SEM).