• Proceedings of the KSR Conference
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• 2005.11a
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• pp.338-343
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• 2005

We have evaluated the structural integrity of a sandwich composite train roof which can find a lightweight, cost saving solution to large structural components for rail vehicles in design stages. The sandwich composite train roof was 11.45 meter long and 1.76 meter wide. The reinforced frame was inserted in sandwich panels to improve the structural performance of train roof structure and had the shape of hollow rectangular box. The finite-element analysis was used to calculate the stresses, deflections and natural frequencies of the sandwich composite train roof against the weight of air-condition system. The 3D sandwich FE model was introduced to simulate the hollow aluminum frames which jointed to both sides of the sandwich train roof. The results shown that the structural performance of a sandwich composite train roof under load conditions specified was proven and the use of aluminum reinforced frame was beneficial with regard to weight savings in comparison to steel reinforced frame.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.06a
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• pp.11-11
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• 2006

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.10
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• pp.1093-1100
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• 2014

The purpose of this paper is to suggest a weight-reduction design method for the hybrid carbody of a high-speed maglev train that uses aluminum extrusion profiles and sandwich composites. A sandwich composite was used on the roof as a secondary member to minimize the weight. In order to assemble the sandwich composite roof and aluminum extrusion side frame of the carbody using welding, a guide aluminum frame located at the four sides of the sandwich composite roof was introduced in this study. The clamping force of this guide aluminum frame was verified by three-point bending test. The structural integrity and crashworthiness of the hybrid carbody of a high-speed maglev train were evaluated and verified according to the Korean Railway Safety Law using a commercial finite element analysis program. The results showed that the hybrid carbody composed of aluminum extrusion frames and a sandwich composite roof was lighter in weight than a carbody made only of aluminum extrusion profiles and had better structural performance.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2005.04a
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• pp.76-79
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• 2005

Bending deformation and energy absorption characteristics of aluminum-composite hybrid tube beams have been analyzed for improvement in the bending performance of aluminum space frame by using experimental tests combined with theoretical and finite element analyses. Hybrid tube beams composed of glass fabric/epoxy layer wrapped around on aluminum tube were made in autoclave with the recommended curing cycle. Basic properties of aluminum material used for initial input data of the finite element simulation and theoretical analysis were obtained from the true stress-true strain curve of specimen which had bean extracted from the Al tube beam. A modified theoretical model was developed to predict the resistance to the collapse of hybrid tube beams subjected to a bending load. Theoretical moment-rotation angle curves of hybrid tube beams were in good agreement with experimental ones, which was comparable to the results obtained from finite element simulation. Hybrid tube beams strengthened by composite layer on the whole web and flange showed an excellent bending strength and energy absorption capability.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.2
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• pp.138-142
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• 2016

In this study, a strength analysis was performed to assess die-cast aluminum alloy brake pedals as an improved alternative to wrought alloys. Aluminum brake pedal shapes are considered to be suitable for the die-casting process. The strength criterion of Volvo trucks was used as the criterion for the pedal strength. The results of this analysis showed that the frame thickness of the aluminum brake pedal must be increased from 12 mm to 18 mm to have a strength superior to that of a steel brake pedal. Additionally, the stress and weight of the aluminum brake pedal were found to be approximately 24% and 26% lower than those of the steel brake pedal, respectively. Mounting tests and strength assessments verified that the proposed die-cast aluminum alloy brake pedal demonstrated sufficient strength.

• Journal of Korea Foundry Society
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• v.25 no.4
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• pp.145-150
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• 2005

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.2
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• pp.250-263
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• 2001

The up and down speed of heddle frames that produce woven cloth by insertion of weft yarns between warp yarns has been increased recently much for productivity improvement, which induces higher inertial stresses and vibrations in the heddle frame. the heddle frame is required to reduce its mass because the heddle frame contributes the major portion of the stresses in the heddle frames during accelerating and decelerating. Conventional aluminum heddle frames have fatigue life of around 5 months at 550rpm due to their low fatigue flexural strength as well as low bending stiffness. In this work, since carbon/epoxy composite materials have high specific fatigue strength(S/p), high specific modulus(E/p), high damping capacity and sandwich construction results in lower deflections and higher buckling resistance, the sandwich structure composed of carbon/epoxy composite skins and polyurethane foam were employed for the high-speed heddle frame. The design map for the sandwich beams was accomplished to determine the optimum thickness and the stacking sequences for the heddle frames. Also the effects of the number of ribs on the stress of the heddle frame were investigated by FEM analyses. Finally, the high-speed heddle frames were manufactured with sandwich structures and the static and dynamic properties of the aluminum and the composite heddle frames were tested and compared with each other.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.337-340
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• 2006

Aluminum extruded profiles have been mostly used only a few automotive parts until now, such as roof rail, sunroof frame and bumper beams. However, Aluminum Extru-form technology, which was recently developed by foreign advanced manufacturer, made it possible to apply the aluminum extruded profiles to suspension parts of passenger and RV cars. It could be obtained by optimized billet casting, extrusion and stretch bending technology. It was possible to have the excellent weight reduction and the competitive price comparing with conventional process of aluminum for automotive parts. Combining additional process technology such as machining and joining, the application can be extended to various automotive parts. We have developed high strength aluminum alloy and fabricated subframe and suspension arm by extruforming process.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.3
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• pp.198-203
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• 2016

Computer-Aided Engineering (CAE) durability analysis and experiments of an aluminum alloy brake pedal were carried out for the car lighter by die casting method. In the CAE analysis, KS standards and criteria of the Volvo Car Corporation were applied, and in the experiment, KS standards were applied. The CAE analysis results show that aluminum alloy brake pedals are stronger than the conventional steel brakes pedals because the yield strength of the aluminum alloy increased by almost 97% over that of steel. Further, the structures of the cylinder and the frame were reinforced with increasing thickness of flame and were changed to suit the die-casting process. Through a durability test based on the KS standard, the strength of a prototype of the aluminum alloy brake pedal was confirmed to be sufficient.

• Journal of the Korean Society for Railway
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• v.6 no.3
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• pp.194-202
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• 2003

To make railway carbody light in weight has advantages at some aspects of both manufacturing and maintenance. Recently, railway carbodys of steel structure have been lightened their weight by using aluminum extrusion plate. for the additional lightening of railway carbody, an optimal design which maintains proper strength and minimizes weight must be achieved. Optimization which is used with finite element analysis for aluminum extrusion plate has the disadvantage of consuming much time. In this paper, the method of equivalent material property which is available to FEA code is established using the method of equivalent stiffness. This method for plate is expanded into the method for railway carbody structure with plates and shells. An objective function is established for maximum stiffness of unit aluminum extrusion plate using established method of equivalent material property. We performed an multi-objective optimization using the penalty function method. As a result, recommendable shapes and sizes of unit extrusion plate for under-frame of high speed train is presented.