• Title/Summary/Keyword: Automotive Hub

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Roll Die Forming Process for Manufacturing Clutch Hub in Automotive Transmission (롤 다이 성형공정을 이용한 변속기 허브 클러치 제조)

  • Ko, D.H.;Lee, S.K.;Kwon, Y.N.;Kim, S.W.;Lee, H.S.;Park, E.S.;Kim, B.M.;Ko, D.C.
    • Transactions of Materials Processing
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    • v.20 no.2
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    • pp.154-159
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    • 2011
  • The roll die forming (RDF) process is a new manufacturing technique for producing gear parts such as clutch drum and clutch hub in automotive transmission. In the RDF process, the material is deformed by a roll installed on a die set. Excellent productivity, low forming load and improved dimensional accuracy have quantitatively been shown to be the benefits of the RDF. In this study, the RDF process is applied to manufacture a clutch hub with a gear shaped part. A finite element (FE) analysis was performed in order to investigate the material strain field and dimension of the final product. Based on the result of the FE analysis, a RDF experiment was performed and the dimensional accuracy of the final product was validated. This work demonstrates that RDF is a process capable of producing a sound clutch hub.

Effect of Shape of Discharge Port on Hydraulic Performance of Automotive Closed Type Water Pump (자동차 밀폐형 워터펌프의 토출구 형상이 수력성능에 미치는 영향)

  • Heo, Hyung-Seok;Lee, Gee-Soo;Bae, Suk-Jung
    • Transactions of the Korean Society of Automotive Engineers
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    • v.14 no.1
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    • pp.39-47
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    • 2006
  • Recent trend in pursuit of high performance and effectiveness for automotive cooling system has changed the application of material for impeller of automotive water pump from metal to high ability engineering resin, which can achieve optimization of design of impeller geometry and realize lightweight high efficiency water pump. Closed type water pump improves hydraulic loss of fluid through the clearance between volute casing and impeller compared with that of the existing open type water pump(Although closed type is heavier than open type for the same size and same material, adoption of plastics can solve the problem.). In the present study, the characteristics of hydraulic performance of closed type water pump were investigated with respect to the angle between shroud and hub of impeller and the shape of discharge port of volute casing. Performance tests were carried out for 4 cases, that is, for 2 impellers and 2 casings. The modification of shape of only discharge port can enhance the hydraulic performance by 10 percent and the pump efficiency by 4-6 percent.

Analysis of Driver's Field of View using a Shadow Algorithm (그림자 계산을 이용한 운전자의 시계성 해석)

  • 김재정;하용수;김용철
    • Transactions of the Korean Society of Automotive Engineers
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    • v.5 no.5
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    • pp.123-131
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    • 1997
  • To ensure drive's field of view, obstruction area generated by a steering wheel, hub and spoke must be considered at the early stage of automobile design. The current approach to computing obstruction area proposed by SAE is based on 2D drafting procedures so that it is not precise and errorprone. In the paper we discuss the novel approach which models the obstruction area as the shadows of the steering wheel, hub and spoke by assuming the human eye as light sources. The approach is based on ray tracing and space transformations for that it can be applied when free form curves are hired to represent the steering wheel, hub and spoke in CAD environment. As a result, it gives more predise and reliable results than SAE approach.

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Outer Bending of a Cold Forged Circle Flange (냉간단조된 후판형 플랜지 돌출부 굽힘성형 공정연구)

  • Kim, D.W.;Shin, Y.C.;Choi, H.J.;Yun, D.J.;Shin, I.C.;Lim, S.J.
    • Transactions of Materials Processing
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    • v.21 no.7
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    • pp.453-458
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    • 2012
  • The flange hub is a main component of an automotive steering system. Dimensional precision of the flange hub is very important for precise control of the steering force. Consequently, the process design for precision forming of a flange hub is required. The teeth of the flange hub are generally formed by bending. In this study, the formability of flange bending was investigated using FE simulations. For the optimum process conditions, the flange is bent by movement of an insert die, and the die angle and bending length are selected as $90^{\circ}$ and 4mm respectively.

Development of Press Forming Technology for the Multistage Fine Tooth Hub Gear (다단 미세 치형 허브 기어의 프레스 성형기술개발)

  • Kim D.H.;Lee J.M.;Lee S.H.;Byun H.S.;Kim B.M.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2005.10a
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    • pp.769-772
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    • 2005
  • This paper deals with the aspects of die design for the multistage fine tooth hub gear in the cold forging process. In order to manufacture the cold forged product fur the precision hub gear used as the ARD 370 system of bicycle, it examines the influences of different designs on the metal flow through experiments and FE-simulation. To find the combination of design parameters which minimize the damage value, the low gear length, upper gear length and inner diameter as design parameters are considered. An orthogonal fraction factorial experiment is employed to study the influence of each parameter on the objective function or characteristics. The optimal punch shape of fine tooth hub gear is designed using the results of FE-simulation and the artificial neural network. To verify the optimal punch shape, the experiments of the cold forging of the hub gear are executed.

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Reduction of the Axial Force of Water Pump Using CFD (전산유체역학을 이용한 워터펌프 축력 저감)

  • Jo, Sok-Hyun;Shin, Dong-Sung
    • Transactions of the Korean Society of Automotive Engineers
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    • v.20 no.3
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    • pp.83-87
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    • 2012
  • Computational Fluid Dynamics (CFD) method has been used to investigate the axial force of automotive water pump. As the excessive axial force can make some unexpected problems like impeller interference and coolant leakage we have focused on finding the cause of axial force and its reduction in this paper. First, we have tested the closed type water pump with and without balance hole by the calculation methods. By examining the pressure contour around the impeller, we have found that the axial force arises not only from the pressure difference around shroud but also from the pressure difference around hub. So we have tested two impellers - one is normal open type impeller and the other is open type impeller with modified hub. The results show that the axial force reduction is about 150~200N for normal one and 700N@3000RPM for modified impeller. And the hydraulic efficiency which is important in aspect of engine fuel efficiency is reduced about 6.5% for normal one but increased 4%@3000RPM for modified impeller.

Behavior and Reduction of Spring-back in a Thin Cold-Forged Product (두께가 얇은 냉간단조품의 스프링백 거동 및 저감설계)

  • Kim, D.W.;Shin, Y.C.;Choi, H.J.;Yoon, D.J.;Lee, G.A.;Kim, Y.G.;Lim, S.J.
    • Transactions of Materials Processing
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    • v.21 no.7
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    • pp.397-402
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    • 2012
  • The flange hub is a main component in an automotive steering system. In general, the flange hub are fabricated by mechanical machining, which is a process where material waste is inevitable. It is well-known that a net-shape cold forging cannot only reduce material waste but can also improve the mechanical strength of the final product. Thus, a forging process design was conducted for production of a flange hub. Significant spring-back occurs around the flange due to its small thickness in conjunction with the residual stresses after forging. In order to achieve the required dimensional accuracy, a process design with appropriate spring-back control is needed. In this study, a modification of the forging die was designed based on FE analysis with the purpose of spring-back compensation. Four kinds of different die designs were evaluated and the optimum design has two times less spring-back than the initial design. The compensation angle of the optimum design is 0.5 degrees. The results have been experimentally confirmed by cold forging of a flange hub and comparing the amount of spring-back between the actual component and the FE analysis.

A study on Net-shape technology of Automotive Lock-up Hub using Cold back pressure forming (배압 성형기술을 이용한 Lock-up Hub의 정형제조 기술에 관한 연구)

  • Kwon, Y.C.;Lee, J.H.;Lee, Y.S.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2007.10a
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    • pp.173-176
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    • 2007
  • The characteristics of the tool system give many effects into the costs and qualities for the finished components. This study proposes a new method for manufacturing of high manufacturing productivity, production process reduction and low cost through back pressure forming. The Lock-up hub is manufactured through many processes, such as upsetting($1^{st}$ Forming), piercing, direct extrusion($2^{nd}$ Forming), final sizing process($3^{rd}$ Forming). In this study, process design for closed-die forging of a Lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of Lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

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Laser Welding of Automotive Transmission Components (자동차 자동변속기 부품의 레이저 용접 적용)

  • Ahn, Young-Nam;Kim, Cheol-Hee
    • Journal of Welding and Joining
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    • v.29 no.6
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    • pp.45-48
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    • 2011
  • In this research, laser welding of automotive transmission components was investigated to replace electron beam welding which is normally conducted under vacuum condition. Fiber laser welding was applied to the automotive transmission components - hub clutch and annulus gear. In the component welding, the laser welding parameters were optimized to eliminate spatters and the end crater. By applying laser welding to the transmission parts, the process time could be reduced up to 70% compared with the current electron beam welding process.

Failure Examples Study for Tribological Characteristics of Drive Shaft and Axle System in Vehicles (자동차 드라이브 샤프트와 액슬 시스템의 트라이볼로지적인 특성에 관한 고장사례 고찰)

  • Lee, Il Kwon;Moon, Hak Hoon;Youm, Kwang Wook
    • Tribology and Lubricants
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    • v.29 no.6
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    • pp.397-402
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    • 2013
  • This study examined the tribological characteristics of the drive shaft and axle system in vehicles. The first drive shaft example contained end play for a CV joint that transferred part of the transmission power to the wheel. The joint part of the drive shaft was deformed because of reduced durability due to wear. Thus, vibrations caused the body to shake and become unbalanced when the drive shaft transferred the power. The second example was the cross-section of a shaft that connected the slip-connection of the propeller shaft on the input side to the yoke flange of the output side; the durability was reduced because of corrosion. End play caused by wear between the bearing and cross-section shaft appeared to cause shaking. In the third example, a grease leak reduced lubrication and thus caused damage to the hub bearing and inside the knuckle. The failure was produced by sticking. The fourth example had noise produced by the gear and gear transfer. This was due to the backlash of the pinion and few ring gears for the differential gear. Therefore, drive shaft and axle systems must be thoroughly checked and managed to minimize and reduce failure phenomena.