Transactions of Materials Processing (소성∙가공)

The Korean Society for Technology of Plasticity and materials processing (한국소성∙가공학회)
권호 표지
DOI QR코드

DOI QR Code

Design of Roll-to-Roll Forming Process for Micro Pattern on the Thin Sheet Metal by Finite Element Analysis

유한요소해석을 이용한 마이크로 박판 미세 패턴 롤-롤 성형공정 설계

  • 차성훈 (서울산업대학교 NID 융합대학원) ;
  • 신명수 (서울산업대학교 NID 융합대학원) ;
  • 이혜진 (한국생산기술연구원 융합생산기술연구부) ;
  • 김종봉 (서울산업대학교 자동차공학과)
  • Received : 2010.01.25
  • Accepted : 2010.03.23
  • Published : 2010.06.01
Download PDF
⟨ Previous Next ⟩

Abstract

Roll-to-roll forming process is one of important metal processing technology because the process is simple and economical. These days, with these merits, roll-to-roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate. However, it is difficult to apply to the forming of micro scale or sub-micro scale pattern. In this study, the roll forming processing for the micro scale is designed and analyzed. The forming of micro pattern for small electric device such as LCD panel by incremental roll forming process is analyzed. Firstly, the optimum analysis conditions are found by several analyses. And then, formability is analyzed for various protrusion shapes at various forming temperatures. The formability is evaluated in terms of filling ratio and damage value. The filling ratio is defined from the tool geometry and critical damage is determined from the analysis of uniaxial tensile test. Finally, optimum forming conditions that guarantee the successful forming are found.

Keywords

References

  1. K. H. Kim, 1999, Design of Forming Rolls using Finite Element, J. Kor. Soc. Ocean Eng., Vol. 13, No. 4, pp. 75-81.
  2. Society of Manufacturing Engineers, Tool and Manufacturing Engineers Handbook, 4thed, Vol. 2, Chapter 8, 1984.
  3. B. Y. Joo, S. W. Baek, S. I. Oh, 2006, Micro Channel Forming With Ultra Thin Metal Foil, Trans. Kor. Soc. Mech. Eng., Vol. 30, No. 2, pp. 157-163. https://doi.org/10.3795/KSME-A.2006.30.2.157
  4. J. Y. Kim, S. M. Joo, H. K. Kim, 2008, Superplastic Micro-extrusion for Micro-gears, Trans. of Kor. Soc. Mach. Tool Eng., Vol. 17, pp. 1-7.
  5. M. Geiger, M. Kleiner, R. Eckstein, N. Tiesler, U. Engel, 2001, Microforming, Annals of the CIRP, Vol. 50/2, pp. 445-459. https://doi.org/10.1016/S0007-8506(07)62991-6
  6. H. Ike, M. Plancak, 1998, Coining Process as a Means of Controlling Surface Microgeometry, J. Mater. Process. Technol., Vol. 80-81, pp. 101-107. https://doi.org/10.1016/S0924-0136(98)00101-0
  7. B.-Y. Joo, S.-I. Oh, 2001, Development of Micro Punching System, Annals of the CIRP, Vol. 50/1, pp. 191-194. https://doi.org/10.1016/S0007-8506(07)62102-7
  8. J. J. Park, H. S. Hwang, Y. S. Kim, H. C. Jeon, 2002, Design of Groove and Preform for Roll Forming of PDP Barrier Ribs, Trans. Kor. Soc. Mech. Eng., Vol. 26, No. 10, pp. 2082-2088. https://doi.org/10.3795/KSME-A.2002.26.10.2082
  9. S. H. Cha, M. S. Shin, J. H. Kim, J. B. Kim, H. J. Lee, J. H. Song, 2009, On the effective analysis method of micro pattern forming on the thin sheet metal, Proc. Kor. Soc. Tech. Plasticity, Spring, pp. 53-56.
  10. L. Wue, 2007, Damage accumulation and fracture initiation in uncracked ductile solids under triaxial loading, Int. J. Solids and Structure, Vol. 44, pp. 5163-5181. https://doi.org/10.1016/j.ijsolstr.2006.12.026
  11. M. L. Wilkins, R. D. Streit, J. E. Reaugh, 1980, Cumulative-strain-damage model of ductile fracture: simulation and prediction of engineering fracture tests. Technical Report UCRL-53058, Lawrence Livermore National Laboratory, October.
  12. G. R. Johnson, T. J. Holmquist, 1989, Test data and computational strength and fracture model constants for 23 materials subjected to large strain, high strain rates, and high temperature. Technical Report LA-11463-MS, Los Alamos National Laboratory.
  13. M. G. Cockcroft, D. H. Latham, 1968, Ductility and the workability of metals., J. Inst. Metals, Vol. 96, pp. 9-33.
  14. T. Wierzbicki, Y. Bao, Y.-W. Lee, Y. Bai, 2005, Calibration and evaluation of seven fracture models, Int. J. Mech. Sci., Vol. 47, pp. 719-743. https://doi.org/10.1016/j.ijmecsci.2005.03.003
  15. D. Li, A. Ghosh, 2003, Tensile deformation behavior of aluminum alloys at warm forming temperatures, Mater. Sci. Eng. Vol. A 352, pp. 279-286.
  16. G. R. Johnson, W. H. Cook, 1983, A constitutive model and data for metals subjected to large strain, high strain rates and temperatures, Proceedings of the 7th international symposium on ballastics, Den Haag, Netherlands, pp. 541-547.

Cited by

  1. Prediction of Wrinkling in Micro R2R Forming and Its Improvement vol.20, pp.1, 2011, https://doi.org/10.5228/KSTP.2011.20.1.42