Papers by Author: June Key Lee

Abstract: Springback has been measured under various process conditions corresponding to those found in real press-stamping operations. The draw bend tests originally developed at Ohio State University (Carden et al., 2002 [1]) were conducted using a range of tool radii, direct controlled constraining forces, and friction conditions. Especially, the draw-bend test was able to apply precise constant restraining force and almost negligible friction by rotating the cylindrical tool with the same speed of drawn sheet strip. Springback angle changes were measured for the bending and sidewall curl regions to find the dependence on the process variables. As expected, tensile restraining force dominates the springback sensitivity, with higher forces reducing springback. The measured springback angles and curvatures were reported for use in modeling of springback of higly anisotropic and asymmetric magnesium alloy sheets.

Abstract: The main goal of this study was to develop the technique of process design and manufacturing for a rectangular deep drawn cup with very narrow width by using finite element analysis scheme and a series of experiments. The manufacturing process of this rectangular cup required several intermediate steps to generate the final shape. The multi-stage deep drawing process was applied to finite element analysis, and a continuous progressive press was employed in a series of experiments. Final specifications of the rectangular deep drawn cup were length of 33.70mm, height of 48.30mm and width of 3.46mm, respectively. In this study, finite element analysis for this drawing process was carried out from the first to the seventh stage, and a series of practical experiment was performed. These simulated results of the rectangular cup were compared with the prototypes of the experiments in view of the deformed shape in each mid-part. The results of finite element analysis showed good agreement with those from the experiments.

Abstract: A numerical approach for forming simulation and manufacturing of micro part, based on the elastic and the rigid-plastic finite element methods by using grain element and grain boundary element, is proposed to simulate MEMS/micro-structural deformation behavior of material during micro forming. The idea is to present the polycrystalline material by an aggregate of so-called grain element that describes the plastic deformations of each individual grain in view of micro-structure. This grain element is connected by grain boundary element to account for shear deformation between grains. The main objective in this study is to develop the reliable finite element model and scheme for micro forming simulation with very thin sheet. The reliability for micro forming analysis is described from the comparisons of the micro-structural deformation behavior between the conventional rigid-plastic finite element analysis and the FE analysis of the developed program with very thin sheet material.