제제 77 장 판재성형가공 장 판재성형가공 (2)(2)

• 하이드로포밍의 유형 하이드로포밍의 유형 : : 튜브 튜브 vs. vs. 판재판재• 튜브 벤딩튜브 벤딩• 하이드로포밍 금형 구조하이드로포밍 금형 구조• 하이드로포밍 제품하이드로포밍 제품• 프레스 설비 및 생산라인프레스 설비 및 생산라인• 성형한계도성형한계도• 판재성형 설계 고려사항판재성형 설계 고려사항• 경제성경제성

Bulging

FIGURE 7.32 (a) Bulging of a tubular part with a flexible plug. Water pitchers can be made by this method. (b) Production of fittings for plumbing by expanding tubular blanks with internal pressure; the bottom of the piece is then punched out to produce a “T” section. Source: After J.A. Schey. (c) Sequence involved in manufacturing of a metal bellows.

Forming with a Rubber Pad

FIGURE 7.33 Examples of bending and embossing sheet metal with a metal punch and a flexible pad serving as the female die. Source: Polyurethane Products Corporation.

Sheet Hydroforming

FIGURE 7.34 The principle of the hydroform process, also called fluid forming.

Tube Hydroforming

FIGURE 7.35 (a) Schematic illustration of the tube hydroforming process. (b) Example of tube hydroformed parts. Automotive exhaust and structural components, bicycle frames, and hydraulic and pneumatic fittings can be produced through tube hydroforming. Source: Schuler GmBH.

Inlet coneInlet cone BMW rear axleBMW rear axle

Drive shaftDrive shaft

•하이드로포밍의 적용 하이드로포밍의 적용 (1)(1)

•하이드로포밍의 적용 하이드로포밍의 적용 (2)(2)

Tube vs. Sheet HydroformingTube vs. Sheet Hydroforming

Production line for tube hydroformingProduction line for tube hydroforming

Tube bending (1)Tube bending (1)

Tube bending (2)Tube bending (2)

Tube bending (3)Tube bending (3)

하이드로포밍의 해석 하이드로포밍의 해석 (1)(1)

하이드로포밍의 해석 하이드로포밍의 해석 (2)(2)

하이드로포밍의 해석 하이드로포밍의 해석 (3)(3)

Die systems for prototyping and productionDie systems for prototyping and production

금형 설계 금형 설계 (1)(1)

Hole punching, Hole punching, notching and notching and bending during bending during hydroforminghydroforming

금형 설계 금형 설계 (2)(2)

Internal pressure as a function of the inside radiusInternal pressure as a function of the inside radius

하이드로포밍 범위 하이드로포밍 범위 (1)(1)

Hydroforming parts for the fitting industryHydroforming parts for the fitting industry

하이드로포밍 범위 하이드로포밍 범위 (2)(2)

Present state of the art in hydroforming Present state of the art in hydroforming using tubes as blanksusing tubes as blanks

하이드로포밍 범위 하이드로포밍 범위 (3)(3)

Achievable branched tube heightsAchievable branched tube heights

The achievable height decreases with an increasing degree of difficultyThe achievable height decreases with an increasing degree of difficulty

하이드로포밍 범위하이드로포밍 범위 (4)(4)

Hydroformed ProductsHydroformed Products

Exhaust gas system (1)Exhaust gas system (1)

• 2,01-16 V-4-cylinder2,01-16 V-4-cylinder

• Heat resistant Heat resistant stainless steelstainless steel

• M3 6-cylinderM3 6-cylinder

• Heat resistant Heat resistant stainless steelstainless steel

Exhaust gas system (2)Exhaust gas system (2)

VW-Hydroformed subframeVW-Hydroformed subframe

for 4WD drive rear axlefor 4WD drive rear axle

Light truck side railLight truck side rail

Engine cradleEngine cradle

• Modified low Modified low carbon steel St 34carbon steel St 34

• Pre tubePre tube 2,600*65*2 mm2,600*65*2 mm

for Opel Astra and Zafirafor Opel Astra and Zafira

Production lines installed since 1997Production lines installed since 1997

Hydroformed R&D-front-endHydroformed R&D-front-end

Frame-type Frame-type hydroforming hydroforming presspress

하이드로포밍 설비 하이드로포밍 설비 (1)(1)

Compacting presses/IHV-pressesCompacting presses/IHV-presses

하이드로포밍 설비 하이드로포밍 설비 (2)(2)

IHV-plant for large-scale series productionIHV-plant for large-scale series production

하이드로포밍 설비 하이드로포밍 설비 (3)(3)

IHV-press/IHV-control/RobotsIHV-press/IHV-control/Robots

하이드로포밍 설비 하이드로포밍 설비 (4)(4)

Press plant 2*50,000 kNPress plant 2*50,000 kN

하이드로포밍 설비 하이드로포밍 설비 (5)(5)

Press plant for the production of Cu T-fittingsPress plant for the production of Cu T-fittings

하이드로포밍 설비 하이드로포밍 설비 (6)(6)

Topic: Topic: 성형한계도성형한계도

* * 한계돔높이 시험한계돔높이 시험

다양한 변형양상을 얻기 위한 시편다양한 변형양상을 얻기 위한 시편

<< 성형한계도성형한계도 (FLD)(FLD) 의 작성과 이용의 작성과 이용 >>

성형한계도의 활용

FIGURE 7.66 Major and minor strains in various regions of an automobile body.

설계 고려사항 (1)

FIGURE 7.67 Efficient nesting of parts for optimum material utilization in blanking. Source: Society of Manufacturing Engineers.

FIGURE 7.68 Control of tearing and buckling of a flange in a right-angle bend. Source: Society of Manufacturing Engineers.

설계 고려사항 (2)

FIGURE 7.69 Application of notches to avoid tearing and wrinkling in right-angle bending operations. Source: Society of Manufacturing Engineers.

FIGURE 7.70 Stress concentrations near bends. (a) Use of a crescent or ear for a hole near a bend. (b) Reduction of the severity of a tab in a flange. Source: Society of Manufacturing Engineers.

FIGURE 7.71 Application of (a) scoring, or (b) embossing to obtain a sharp inner radius in bending. However, unless properly designed, these features can lead to fracture. Source: Society of Manufacturing Engineers.

경제성 분석

FIGURE 7.72 Cost comparison for manufacturing a cylindrical sheet-metal container by conventional spinning and deep drawing. Note that for small quantities, spinning is more economical.