• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.11
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• pp.1705-1713
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• 2010

The reliable fatigue life for hybrid composite joint structures was estimated by a statistical method for evaluating fatigue life; the results of the fatigue test varied widely. Cyclic bending tests were performed on a cantilever beam with a hybrid composite joint, which was developed for the body of a low-floor bus. In order to estimate the fatigue life of the hybrid composite joint structure by comparing the data obtained during the fatigue tests, the most suitable probabilistic density function among the normal, lognormal, and Weibull distributions was selected. The probabilistic-stress-life (P-S-N) curves calculated by using the selected Weibull distribution was suggested for process of statistical fatigue life estimation and reliability design.

• Journal of the Korean Society for Railway
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• v.10 no.1 s.38
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• pp.39-44
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• 2007

This rafer explains a durability test of a large train car body made of carbon/epoxy composite material. The composite car body with the length of 23m was manufactured as a sandwich structure composed of an aluminum honeycomb core and CF1263 woven fabric carbon/epoxy faces. In order to evaluate durability of the composite car body, it was excited by two 500kN capacity hydraulic actuators installed underneath the body bolster. The natural frequency of the composite car body under full weight condition was found to be 4.33Hz. Based on this result, the excitation frequency and displacement of 5Hz and ${\pm}1.0mm$, respectively, were used as inputs for the durability test. The test was conducted for $2{\times}10^6$ cycles. During the test, the nondestructive tests using X-ray radiography and dye penetration method was performed to determine the presence of the cracks. Upon completion of the test, no cracks were found.

• Proceedings of the KSR Conference
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• 2011.10a
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• pp.2644-2649
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• 2011

The purpose of this study is to propose the modular design of hybrid lightweight carbody structures made of sandwich composites and aluminum extrusion. The sandwich composites were used for secondary structures to minimize the weight of carbody, and the aluminum extrusions were applied to primary structures to improve the stiffness of carbody and manufacturability. Key requirements were defined for the modular design of hybrid carbody, and the applied parts of sandwich composites were determined through the topology optimization analysis. Consequently, feasibility of enhancing mass saving and maintainability in modular hybrid carbody design were presented, comparing with the carbody structures made of aluminum extrusion or sandwich composites only.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2004.10a
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• pp.185-188
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• 2004

Regarding some of the components of the Korean Tilting Train eXpress(TTX), the lightweight-vehicle development was mainly focused to this study, and so as using the materials, the existing material, steel or aluminum carbody was changed to the composite carbody with both design and manufacturing methods. Therefore the evaluation of the performance of joint strength between composite and metallic boundary area, especially the under frame and the carbody was required, and the compressive and the bending tests were conducted as the sub-scale specimen. In this evaluation, there was involved the sufficient strengths at the joint area between the underframe and the carbody, and is resulted as the increment of the safety factor through the observation of failure conditions.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2004.10a
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• pp.212-215
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• 2004

The hybrid composite carbody structures were considered as the carbody system of Korean Tilting Train eXpress(TTX) to achieve the lightweight design. The TTX carbodies are composed of the carbody shell made of the sandwich composite structure and the undeframe made of the metal structure. The sandwich structures were used to minimize the weight of carbody, and the metal underframe was used to modify the design easily and to keep the strength of underframe by the installation of the electrical equipments. The sandwich carbody structures will be cured in an autoclave. In this paper, the manufacturing processes of the TTX carbody structures were introduced briefly.

• Proceedings of the KSR Conference
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• 2004.10a
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• pp.461-466
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• 2004

The hybrid composite carbody structures were considered as the carbody system of Korean Tilting Train eXpress(TTX) to achieve the lightweight design. The TTX carbodies are composed of the carbody shell made of the sandwich composite structure and the undeframe made of the metal structure. The sandwich structures were used to minimize the weight of carbody, and the metal underframe was used to modify the design easily and to keep the strength of underframe by the installation of the electrical equipments. The sandwich carbody structures will be cured in an autoclave. In this paper, the manufacturing processes of the TTX carbody structures were introduced briefly.

• Proceedings of the Korean Reliability Society Conference
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• 2006.05a
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• pp.357-361
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• 2006

Fatigue fracture behavior of a hybrid joint part with bolting was evaluated in comparison to the case of static fracture. Hybrid joint part specimens for bending test were made with layers of CFRP and aluminum honeycomb. Characteristic fracture behaviors of those specimens were obviously different under static and cyclic loads. Static bending load showed the shear deformation at the honeycomb core, whereas cyclic bending load caused the delamination between CFRP skin layers and honeycomb core. Experimental results obtained by static and fatigue tests were considered in modifications of design parameters of the hybrid joint.

• Journal of Welding and Joining
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• v.27 no.6
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• pp.9-16
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• 2009

In this paper, the coaxial monitoring system to capture image of weld pool was developed in laser-arc hybrid welding. In order to obtain the reliable image, green laser was used as a illumination system and measuring components such as band pass filter, ND (Neutral Density) filter and shutter speed was designed and optimized. Using this monitoring system, weld pool images were captured according to laser power, welding speed, welding current and interspace between laser and arc through the experiment. ANOVA (Analysis of Variation) was carried out to identify the influence of process variables on bead widths extracted from captured images of monitoring system. Welding speed and current were major factor to affect weld pool.

• Composites Research
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• v.19 no.1
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• pp.9-14
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• 2006

Experimental investigation on heat transfer ratio was firstly performed with three types of sandwich panels such as the Carbon/Epoxy Skin-Aluminum Honeycomb and Balsa Core Sandwich Panel of 37mm thickness, the Carbon/Epoxy Aluminum Skin-Honeycomb Core Sandwich Panel of 57mm thickness (including insulator) and the Carbon/Epoxy Skin-Aluminum Honeycomb Core Sandwich Panel of 37mm thickness based on the KS F 2278:2003(Insulation test method of windows). In additional to this investigation, experimental tests were also done for evaluation of heat transportation ratio with the Aluminum Skin- Aluminium Honeycomb Sandwich Panels of 27mm and 35mm thickness, and Aluminum Skin-Foaming Aluminum Sandwich Panel of 27mm thickness by the KS F2277:2002 (Insulation measuring method of construction component-Calibration heat box method or protective heat box method). In this study, it was found that the larger net heat transfer cross sectional area between the skin and the sandwich core is given, the higher heat transportation ratio occurs. It was also found that the hybrid type insulation had better insulation characteristics compared to the non-hybrid type insulation.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.1
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• pp.87-95
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• 2012

In recent years, laser-arc hybrid welding has begun to be adopted for assembly welding of automotive bodies and parts, because the hybrid welding process can weld lapped steel sheets having a larger gap than is possible with laser welding. In this paper, to predict the twist deformation by the hybrid welding when brackets are welded in B pillar of a passenger car, the residual stress using CAE is analyzed and the deformation result of CAE is compared with the measured deformation. First of all, after modeling heat source as intended to be expressed with laser-arc hybrid welding method, heat source fitting is done with welding conditions and a section of welding part obtained through specimen test. In case of heat source functions, laser used conical source and arc used double ellipsoid source. Through the local model analysis, elements which are located in the center of the model are selected. The elements are called WME(Welding Macro Element). This WME is extruded in the welding lines and welding phenomenon of complex parts is accomplished. The deformation amount after hybrid welding is got through a simulation, the validity of simulation is verified by measuring the panel and comparing with the simulation result.