• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.368-368
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• 2007

• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.1
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• pp.45-50
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• 2011

Hot-Press-Forming (HPF), an advanced sheet metal forming method using stamping at a high temperature of about $900^{\circ}C$ and quenching in an internally cooled die set, is one of the most successful forming process in producing crash-resistant parts such as pillars and bumpers with complex shape, ultrahigh strength, and minimum springback. To optimize conditions of a forming quality in HPF process and secure a safe product without any failures, such as fractures and wrinkling, the simulations based on the coupled thermo-mechanical analysis for a hot-press-formed lower control arm are applied with Taguchi's orthogonal array experiment. Three factor variables - the friction coefficient, blank shape, and hole location for burring - are selected to be optimized. The most effective condition of a forming quality for a hot-press-formed lower control arm is suggested. The simulation results are confirmed with experimental ones.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.453-458
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• 2008

Under driving condition, A vehicle experiences various kinds of loads, which brings on the buckling and fracture of suspension systems. Lower control arm (LCA), which consists of 2 bush joints and 1 ball joint connection, is the one of the most important parts in the suspension system. The bush joints absorb the impact load and reduce the vibration from the road. When analyzing the LCA behavior, it is important to understand the material properties and boundary conditions of bushing systems correctly, because of the nonlinearity characteristics of the rubber. In this paper, in order to predict the large scale deformation of the LCA more precisely, three factors are newly suggested, that is, coupling of bush stiffness between translation and rotation, bush extraction force and maximum rotation angle of ball joint. LCA stiffness is estimated by CAE and component test. Analysis and test results are almost same and the validity of considering three factors in LCA analysis is verified.

• Transactions of the Korean Society of Automotive Engineers
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• v.22 no.2
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• pp.100-106
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• 2014

Lower control arm (LCA) is a part of chassis in automotive. Performances of LCA such as stiffness, durability and permanent displacement must be considered in design optimization. However it is hard to consider different performances at once in optimization because these are measured by different commercial tools like Radioss, Abaqus, etc. In this paper, firstly, we construct the integrated design automation system for LCA based on Matlab including Hypermesh, Radioss and Abaqus. Secondly, Akaike information criterion (AIC) is used for assessment of reliability of LCA. It can find the best estimated distribution of performance from limited and discrete stochastic information and then obtains the reliability from the distribution. Finally, we consider tolerances of design variables and variation of elastic modulus and achieve the target reliability by carrying out reliability-based design optimization (RBDO) with the integrated system.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.592-597
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• 2001

An automobile lower arm has been fabricated in a prototype form by hydroforming with the aids of numerical analysis and experiments. For the numerical process design, a program called HydroFORM-3D developed here on the basis of a rigid-plastic model, has been applied to the lower arm hydroforming. The friction calculation between die and workpiece has been dealt carefully by introducing a new scheme in three-dimensional surface integration. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as internal hydraulic pressure, axial feeding, and tool geometry has been performed. Results obtained from numerical simulation for a lower arm in hydroforming process are compared with a series of experiments. The comparison shows that the numerical analysis successfully provides the manufacturing information on the lower arm hydroforming, and it predicts the geometrical deformation and the thinning.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.139-142
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• 2003

In this study, casting/forging process was used to produce an aluminum lower control arm for automobiles. Firstly, casting experiments were carried out to get an enhanced preform for forging the lower control arm. In the casting experiment, the effect of an additive, Sr, on the mechanical properties such as tensile strength and elongation and the microstructure of a cast preform were investigated. And a finite element analysis was peformed to determine an optimal configuration of the cast preform. Lastly, a forging experiment was carried out to make the final product of aluminum lower control arm by using the above cast preform. In the casting experiments, when 0.025% Sr was added into molten A356, the maximum values of tensile strength and elongation of the cast preform were obtained. In the forging experiment, It was confirmed that the optimal configuration of a cast preform predicted by FE analysis was very useful. The cast/forged product using designed preform was made without any defects.

• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.6
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• pp.1-6
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• 2010

Aluminum rear lower arm is designed for luxury sedan and manufactured by hollow sand casting in the present study. Here we present the relationship between local microstructure and coupon tensile test in the rear lower arm. The characteristics of the local tensile deformation are supposed to be dependent upon Si distribution and DAS (dendrite arm spacing). Si distribution affects the yield strength and DAS affects the elongation of local area in the part, respectively.

• Transactions of Materials Processing
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• v.10 no.7
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• pp.534-542
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• 2001

Tubular hydroforming has attracted increased attention in the automotive industry recently. In this study, a professional finite element program for analysis and design of tube hydroforming processes, has been developed, called HydroFORM-3D, which is based on a rigid-plastic model. With the developed program HydroFORM-3D, the hydroforming process for an automobile lower arm is analyzed and designed. The manufacturing process for a lower arm consists of tube bending, preforming, and final hydroforming. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as internal hydraulic pressure, axial feeding, and tool geometry is required. This paper describes the influences of forming conditions on the hydroforming of a lower arm by using simulation to predict strain and tube shape during bending, preforming, and final hydroforming processes.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.2
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• pp.214-218
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• 2011

In order to survive in turbulent and competitive markets, automotive part manufacturers try efforts to develop new manufacturing technologies for ultra-lightweight, high-intensity and environmentally-friendly parts. Most of front lower arm is manufactured by welding process between upper- and lower panel which are produced by press stamping process. Because lower arm mounted on the cross member parts is one of the important complementary parts. So, to improve safety and lightweight of these parts, hybrid technologies are used in this paper. As hybrid technologies are applied to be front sub-frame, rear cross member and other chassis parts as well as front lower arm, the 20% lightweight has been achieved compared with existing steel parts.

• Transactions of the Korean Society of Automotive Engineers
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• v.9 no.6
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• pp.160-169
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• 2001

To predict busting failure in tubular hydroforming, the criteria for ductile fracture proposed by Oyane is combined with the finite element method. From the histories of stress and strain in each element obtained from finite element analysis, the fracture initiation site is predicted by mean of the criterion. The prediction by the ductile fracture criterion is applied to three hydroforming processes such as a tee extrusion, an automobile rear axle housing and lower am. For these products, the ductile fracture integral I is not only affected by the process parameters, but also by preforming processes. All the simulation results show the combination of the finite element analysis and the ductile fracture criteria is useful in the prediction of farming limit in hydroforming processes.