• 한국철도학회논문집
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• 제2권2호
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• pp.1-5
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• 1999

Based on the development of designed technology for aluminum carbody. the prototype aluminum carbody has been constructed. All extrusion profiles required for the carbody has been produced and their quality has also been proven. For sound construction. welding technology to join aluminum extrusion profiles has been developed and jigs for precise assembly of blocks have been made. The aluminum carbody for urban subway train has been completed with the required chamber being set and the welding deformations being constrained by jigs. The safety of the carbody structure has also been proven by the static load test. And also, painting technology has been developed and the surface of the carbody has been pre-treated and painted. The developed technology to construct the aluminum carbody can be used in mass production of aluminum cars ordered by domestic and foreign customers.

• 한국철도학회:학술대회논문집
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• 한국철도학회 2011년도 정기총회 및 추계학술대회 논문집
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• pp.2679-2683
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• 2011

The purpose of this study is to develop automated structural design and analysis aided-program of aluminum extrusion carbody structures for railway vehicle. This developed program is possible to perform simultaneously structural design and design verification of aluminum extrusion profiles independent of expertise and experience of design engineers. Design engineers was able to design it using database of existing aluminum extrusion profiles or user-defined function. The design verification was programmed to evaluate its structural integrity according to Korean Railway Safety Law or Urban Transit Safety Law. Also, this program could automatically generate an executable file of various commercial finite element program and CAD files such as stp and iges by GUI environment applications using MFC(Microsoft Foundation Classes). In conclusion, it is expected to contribute to reduce product development time and improve product quality of aluminum extrusion profile and structures in railway industry.

• 한국철도학회:학술대회논문집
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• 한국철도학회 2009년도 춘계학술대회 논문집 특별세미나,특별/일반세션
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• pp.311-320
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• 2009

Most advanced countries are researching to apply light weight materials far rolling stock because weight reduction for railway body derives cost-saving, energy-saving, and high-speed. Likewise, current Korea rolling stock field makes arduous effects of weight-reduction, miniaturization, and high-efficiency to achieve a high-speed railway. Aluminum becomes suitable material for these projects because it is much lighter than steel or stainless. Manufacturing the railway car body by using the Aluminum is increasing because Aluminum is not bringing the corrosion by unique oxidation-passivate. Aluminum extrusion profile far railway body requires a high mechanical property, accurate shape dimension, and stable quality because the railway body is composed with many different kinds of extruded profiles. Therefore, it is necessary to research about Aluminum precision-extrusion technology to maintain exit temperature and die load. The goal of this project is applying the Aluminum extrusion profile to next-generation railway car body by developing the Aluminum extrusion profile according to precision-extrusion technology which may maintain isothermal exit temperature.

• 소성∙가공
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• 제16권7호
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• pp.555-560
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• 2007

This paper shows some achievements at bending of extruded aluminum profiles during the extrusion process. The conventional process for the production of bent profiles involves a successive extrusion, stretching, and bending of the profiles. Conventional bending methods can not meet demands far precision and cost-effective production in some cases, due to cross sectional deformation, irregular decrease of tube wall thickness and a complication of the process design. An estimation of spring-back required for precision of the bending radius can not always be achieved by the over bending of the profile. Since the profile is hot during the bending process, the spring-back phenomenon can be avoided. This means that an additional bending process is not necessary. Consequently, flexible bending can be achieved with cost reduction and quality improvement. Experimental tests were completed to study the relationship between curvature radius of profile and position of guide on the extrusion for vehicle bumper. A7108 is applied as a billet material in order to increase strength. The overall correlation between the experimental and numerical results is good. It is therefore concluded that the present method provides an efficient means for the constant curvature extrusion process.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 추계학술대회 논문집
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• pp.37-41
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• 2000

Extruded Profiles of Aluminum alloys have been widely used as parts and frames in mechanical and construction structures. Nowadays, mechanical processing of extruded Al alloy profiles is often employed for various industrial applications. Especially, the bending process is more and more applied and the process is greatly influenced by the distributed mechanical properties in the extruded profiles. Due to large reduction of area or extrusion ratio in ordinary production of extruded profiles, anisotropy is naturally induced by large severe deformation during the extrusion process. Therefore, the anisotropy properties play a great role in the bending process, as a post processing of extruded profiles and errors will be involved when the extruded profiles are treated as isotropic material, ignoring the induced anisotropy in the thin-walled extruded product. In the present work, the anisotropic material change is simulated, as a simplified method, employing Barlats six-component yield criterion in the rigid-plastic finite element method. Finite element computations are carried out for extrusion of a thin-walled part.

• 소성∙가공
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• 제26권2호
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• pp.115-120
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• 2017

Porthole extrusion process is a very effective metal forming process to produce aluminum profiles with hollow sections. The structure of porthole extrusion die is very complex. In this process, the billet is divided by porthole bridge, and then the divided billet is welded in the welding chamber. The welding pressure in the welding chamber is very important. The higher welding pressure improves the quality of the aluminum profiles. Therefore, the objective of this study is to develop a new porthole extrusion die for improving the welding pressure in the welding chamber by using numerical analysis. The effectiveness of the new porthole extrusion die was verified by using numerical analysis. Through numerical analysis, the welding pressures in the welding chamber between the new porthole die and the conventional porthole die were compared with each other.

• 한국철도학회:학술대회논문집
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• 한국철도학회 2002년도 춘계학술대회 논문집
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• pp.364-369
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• 2002

The purpose of this paper is to introduce the concept design and the structural strength of the double-deck rolling stock vehicle. Aluminum is very useful material for the carbody structure due to its characteristic of light weight. Large alumillum extrusion profiles(panels) have toe of merits such as easy production of complicated shapes, reduction of welding and cutting lines, and cutting down the labor cost. AED type is being applied to the standard EMUs and the EMUs Kwangju subway in Korea. Light material recommended the double-deck rolling stock vehicle because the center of gravity of the train is higher and its weight is heavier than those of the normal vehicle. So we applied the technology of the large aluminum extrusion profiles(panels) to the double-deck vehicle. We performed the structural strength analysis and examined its safety.

• 한국산학기술학회논문지
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• 제19권7호
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• pp.50-55
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• 2018

압출기술에서 중요한 것은 금형의 설계 및 제작이며, 원하는 형태의 압출이 원활히 이루어지는 동시에 금형의 수명을 최대한 연장하고 효율성을 높이기 위한 금형의 설계가 필수적이다. 압출 온도, 압출 속도 등이 압출시의 주된 변수이며, 압출비 및 재료의 물성, 압출 형태에 따라 각기 다른 조건이 부가되어야 한다. 본 연구에서는 고속전철 내외장재 부품용 알루미늄 6xxx 계열 주조 합금의 압출공정에 대해 연구하였다. 6063, 6061, 6N01, 6005, 5083 and 6060 알루미늄 합금의 압출 금형 단면을 설계하였으며 이에 대한 실험을 실시하였다. 또한, 빌렛온도, 압출온도 및 재료의 변화에 따른 압출 압력과 같은 압출 조건들을 분석하였다. 6063 알루미늄 합금이 가장 낮은 온도와 압력에서 압출이 가능한 반면 6061 합금은 가장 높은 온도와 압력에서 압출이 가능하였다. 이들 실험결과로부터 수립된 조건들을 이용하여 성공적인 압출제품을 제조할 수 있었다.

• 대한기계학회논문집A
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• 제32권4호
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• pp.327-332
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• 2008

The effectiveness of vehicle parts made through extrusion is in the limelight because of the advantages of high strength stiffness materials can be produced and the number of processes can be drastically reduced. Therefore, the parts should have sufficient stiffness and be lightweight enough to improve fuel efficiency. However, the application of extruded aluminum requires pre-bending technologies that can manufacture the complex designs profiles demanded by vehicle parts. The aim of this research is that the development of the variable curvature extrusion technology that can produce a variety of curvature. In order to produce a variable curvature, the guide transfer speed and transfer time should be controlled properly. The guide transfer speed and transfer time were examined by the theoretical analysis. A model was developed to simulate the deformation behaviors of extrusion and bending process from the symmetric bumper with range of radii from 1863mm to 2163mm. The theoretical analysis and FE analysis were verified through experimental method.

• 대한기계학회논문집A
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• 제38권10호
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• pp.1093-1100
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• 2014

본 논문의 목적은 알루미늄 압출재와 샌드위치 복합재를 사용한 초고속 자기부상 열차의 하이브리드 차체 경량화 설계를 제안하는 것이다. 샌드위치 복합재는 무게 감소를 위해 2차 부재인 루프에 적용되었다. 용접에 의한 샌드위치 복합재 루프와 알루미늄 압출재 사이드 프레임과 접합시키기 위해 샌드위치 복합재 네 옆면에 가이드 알루미늄 프레임을 갖도록 고안하였다. 가이드 알루미늄 프레임의 체결력은 3점 굽힘 시험을 통해 검증하였으며, 차체의 구조 안전성 및 충돌 안전도는 상용 유한요소해석프로그램을 이용하여 철도안전법에 따라 평가하고 검증하였다. 연구결과, 알루미늄 압출재와 샌드위치 복합재로 이루어진 하이브리드 차체는 알루미늄 압출재로만 이루어진 차체에 비해 무게 절감 효과와 향상된 구조 성능을 얻을 수 있다.