• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.1105-1106
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• 2010

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2011.06a
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• pp.1235-1236
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• 2011

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.3
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• pp.77-82
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• 2012

It is well known that the targeted fuel efficiency could only be achieved by more than 40% reduction of the vehicle weight through improved design and extensive utilization of lightweight materials. In order to obtain the goal of the weight reduction of automobiles, the researches about lighter and stronger rear sub-frame have been studied without sacrificing the safety of rear sub-frame. In this study, the weight reduction design process of rear sub-frame could be proposed based on the variation of von-Mises stress contour by substituting an AA6061 (aluminum 6061 alloy) having tensile strength of 310 MPa grade instead of SAPH440 steels. In addition, the stress ratio variations (stress over fatigue limit) of the rear sub-frame were examined and compared carefully. It could be reached that this approach method could be well established and be contributed for light-weight design guide and the optimum design conditions of the automotive rear sub-frame development.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.9
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• pp.1-6
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• 2018

Hydro-forming technology has spread dramatically throughout automotive industry over the last 20 years. This technology has many advantages for automotive applications in terms of better structural integrity of the parts, lower cost from fewer parts, material savings, weight reduction, lower springback, improved strength, durability, and design flexibility. In this study, various simulation technologies were developed to investigate the formability of hydro-forming components. Through this technology, to establish the effective forming process for appropriate components design, the bending process, pre-forming process, die closing process, etc. were considered for good forming. This paper proposes the forming amount, section length (corresponding to the hydro-forming press capacity), and minimum curvature (curvature effect evaluation according to the hydro-forming pressure) among the considerations in the design of the hydro-forming part. In addition, a design method is proposed for hydro-forming molding by carrying out cross section analysis of a real sub-frame part for automobiles. The effects of pre-bending, axial feed, hydraulic pressure, press load, and friction among the hydro-forming process parameters were analyzed. Therefore, whether these processes are necessary factors for hydro-forming were examined.

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.3
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• pp.38-43
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• 2008

The hydroforming technology has been spreaded dramatically in automotive industry last 10 years. Itmay cause many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower springback, improved strength and durability and design flexibility. In this study, the whole process of rear sub-frame parts development by tube hydroforming using steel material having tensile strength of 440MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydroformability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape in automotive rear sub-frame by hydroforming process were carefully investigated. Overall possibility of hydroformable sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydroforming. In addition, all the components of prototyping tool are designed and interference with press is examined from the point of geometry and thinning.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.222-225
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• 2008

Due to new requirements of the automotive industry, concerning lightweight and non-corroding construction, new production methods, The Hot Air Forming process of aluminum alloys are of special interest. The disadvantage of aluminum alloy is the poorer formability compared to steel. The Hot Air Forming process is one of the forming process receiving recent attention. In the current study, Fabrication of aluminum rear subframe has been attempted using seam and seamless aluminum tubes. On the base of hot workability of the extruded tube and PAM-STAMP simulation results, Optimum condition for fabricating aluminum rear sub(lame parts by Hot Air Forming could be determined.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.26-29
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• 2008

Recently, the hydroforming of high strength aluminum tubes has many studies and applications in manufacturing industry, especially in automotive industry. But high strength aluminum tube has limited expansion capability at most 15% at normal temperature. New manufacturing process, called hot air forming, is introduced to apply aluminum tube to the automotive sub frame components which have complex shape and require high expansion ratio about 40%. The process is carried out at the elevated temperature above $500^{\circ}C$, so numerous material properties and process parameters related to high temperature should be investigated and determined to get a sound product. In this paper, the hot air forming process of automotive sub frame was investigated. The effect of the forming parameters such as the temperature of tool, axial feeding and gas pressure are analyzes by using explicit finite element method.

• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.5
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• pp.45-49
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• 2010

The automotive industry has shown a growing interest in tube hydroforming during the past years. The advantages of hydroforming (less thinning, a more efficient manufacturing process, etc.) can, for instance, be combined with the high strength of extra high strength steels, which are usually less formable, to produce structural automotive components which exhibit lower weight and improved service performance. Design and production of tubular components require knowledge about tube material and forming behavior during hydroforming and how the hydroforming operation itself should be controlled. These issues are studied analytically in the present paper. In this study, the whole process of rear sub-frame parts development by tube hydroforming using AA6061 material is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Engineering) to confirm hydroformability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape in automotive rear sub-frame by hydroforming process were carefully investigated. Overall possibility of hydroformable rear sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending and hydroforming. In addition, all the components of prototyping tool are designed and interference with press is examined from the point of geometry and thinning.