• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.254-259
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• 2007

Dent resistance is an important characteristic to avoid damage on automotive outer panels. From a practical point of view, dents can be caused in a number of ways. Considering doors as an example, denting can occur from stone impacts or from the careless opening of an adjacently parked vehicle door. Denting can occur where the door surface is smooth and may not have sufficient curvature to resist dent. These exterior body parts are designed to improve dent resistance using a combination of work hardening and bake hardening. In brief, dent is affected by the shape of the parts and the material properties such as yield strength, strain and thickness. In this work, forming of door outer panel is investigated by Taguchi method. Main parameters are yield strength, thickness, blank size, blank holding force and so on. For the given value of design parameters, forming analysis of the eighteen cases are carried out according to L18 orthogonal array. After comparing the performance by simple conversion of simulation results into dent resistance, the final suggestion of the forming parameters is verified for the optimal improvement of dent resistance.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.4
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• pp.455-462
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• 2015

A feature line is a visually noticeable creased line on outer automotive panels. Feature lines play an important role in creating a good impression of a car. Even though the manufacturing quality of feature lines is important, it is difficult to achieve the designed shape owing to the springback of sheet metal. The current study presents five methods of making samples that will be used in a visual experiment to discover a quality control quantitative manufacturing allowance for feature lines. Measurement and inspection methods for the samples are also presented. The results show that plunge machining is the most accurate way to make the desired shape, and that wrapping the machined surface with sheet film is an appropriate way to emulate the roughness and visual texture of the painted outer panels of a car.

• Transactions of Materials Processing
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• v.7 no.6
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• pp.586-593
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• 1998

In recent automotive industries there has been significant increase in applications of computer simulation to the manufacturing of stamping dies for inner and outer body panels which greatly affect durability and aesthetic quality of automobiles. Enhancement of die quality and reduction of total die manufacturing time and consequently manufacturing cost are the visible outcome. However to successfully apply the result of simulation by a commercial package to the die manufacturing development of an optimal die manufacturing process is required upon the completion of analysis of forte and shortcoming of available sheet metal forming softwares. Based on the results of numerical analysis of front door outer panel forming. this paper evaluates the applicability of simulation results to the real die manufacturing for automotive body panels. Also it attempts to select an optimal die manufacturing process including design machining and tryout. Lastly it discusses the expected effects by adopt-ing the selected process in a real stamping die manufacturing facility.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.280-286
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• 2015

Hemming is used to connect two sheet metal components by folding the edge of an outer panel around an inner panel to create a smooth edge. The minimization of hemming defects is critical to the final quality of automobile products because hemming is one of the last operations during fabrication. Designing the hemmed part is not easy and is influenced by the geometry of the bent part. Therefore, the main problem for automotive parts is dimensional accuracy since formed products often deviate geometrically due to large springback. Few numerical approaches using 3-dimensional finite element model have been applied to hemming due to the small element size which is needed to properly capture the bending behavior of the sheet around small die corner and the comparatively big size of automotive opening parts, such as doors, hoods and deck lids. The current study concentrates on the 3-dimensional numerical simulation of hemming for an automotive door. The relationship between the design parameters of the hemming operation and the height difference defect is shown. Quality improvement of the automotive door can be increased through the study of model parameters.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.2
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• pp.41-49
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• 2007

More diversified and strengthened safety regulations require higher safety vehicle with less weight. The structural foam can play a role for restraining section distortion of main body members undergoing bending collapse at vehicle crash. In this study, using structural foam modeling technology, validated in previous work, the bending collapse characteristics were evaluated for two types of circular and actual vehicle body frame sections. With changing the foam filling method, outer panel thickness and section shape, load carrying capability and absorbed energy were observed. The results indicate valuable design strategy for effectively elevating bending collapse performance of body members with foam filled.

• Transactions of Materials Processing
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• v.25 no.1
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• pp.29-35
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• 2016

In the current study, finite element analysis was conducted for the press hemming of automotive panels in order to predict various hemming defects such as roll-in and turn down. The analysis used the exact punch movement based on the cam location and considered the sealer between the inner and outer panels with an artificial contact thickness. The analysis results quantify the hemming defects especially at the flange edge in the matching region of the head lamp. A design of experiments along with the parameter study was used to obtain the optimum process parameters for minimizing hemming defects. The optimization process selects the intake angle, bending angle of the hemming punch, and the flange height of the outer panel. The optimum design process determines an appropriate tool angle and flange height to reduce the roll-in and turn-down as compared to the initial design.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.6
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• pp.50-61
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• 2007

The structural stiffness, strength and stability on the bodyshell and floor structures of the Korean Low Floor Bus composed of laminate, sandwich panels and metal reinforced frame were evaluated. The laminate composite panel and facesheet of sandwich panel were made of WR580/NF4000 glass fabric/epoxy laminate, while aluminum honeycomb or balsa was applied to the core materials of the sandwich panel. A finite element analysis was used to verify the basic design requirements of the bodyshell and the floor structure. The use of aluminum reinforced frame and honeycomb core was beneficial for weight saving and structural performance. The symmetry of the outer and inner facesheet thickness of sandwich panels did not affect the structural integrity. The structural strength of the panels was evaluated using Von-Mises criterion for metal structures and total laminate approach criterion for composite structures. All stress component of the bodyshell and floor structures were safely located below the failure stresses. The total laminate approach is recommended to predict the failure of hybrid sandwich composite structures at the stage of the basic design.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.68-75
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• 2008

This paper investigates the correlation between surface roughness and gloss of aluminium sheet painted waterborne paint. One customer criterion of automotive quality is the as-painted appearance of the final products. Especially, the current emphasis on control of surface roughness of sanded aluminium sheet has been prompted by the automotive industry's concern with the as-painted appearance. because the influence of such characteristics on paintability, and painted appearance is important in defining outer panel requirements for automobile. This paper is dedicated primarily to the issue of painted appearance and reviews for improvement of roughness. The conclusions are obtained as follows ; 1) Painted aluminium sheet appearance is strongly affected by surface roughness of base-metal and influenced by sand paper and sanding method. 2) The painted appearance of aluminium sheets was determined and related to surface roughness parameters, combination of sand paper.

• Journal of the Korean institute of surface engineering
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• v.34 no.4
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• pp.313-320
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• 2001

It is well known that the amount of hot-dip Zn coated sheet steels used for automotive is rapidly increasing. As hot-dip steel sheets show good corrosion resistance and excellent formability, the demand for outer panel of automotive has been increased in order to satisfy with the requirement of high surface qualify. There are many kinds of factors influencing on the surface quality and the dross control in the galvanising bath is regarded as one of the most important thing. In this study the characteristic and growing behavior of dross in the galvanizing bath were investigated and the effect of dross on the surface defect of GA was surveyed. The dross defects on the GA sheet steels result from bottom dross whose diameter are larger 50$\mu\textrm{m}$ in the Zn pot. Dross-free state exist for about 30 hours from starting time of GA production.

• Transactions of Materials Processing
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• v.20 no.2
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• pp.160-166
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• 2011

Weight reduction while maintaining functional requirements is one of the major goals in the automotive industry. The use of lightweight magnesium alloys offers great potential for reducing weight because of the low density of these alloys. However, the formability and the surface quality of the final magnesium alloy product for auto-body structures are not acceptable without a careful optimization of the design parameters. In order to overcome some of the main formability limitations in the stamping of magnesium alloys, a new approach, the so-called "hybrid technology", has been recently proposed for body-in-white structural components. Within this approach, necessary level of mechanical joining can be obtained through the use of lightweight material-steel adhesion promoters. This paper presents the development process of an automotive hybrid hood assembly using magnesium alloy sheets. In the first set of material pairs, the selected materials are magnesium alloy AZ31B alloy and steel(SGCEN) as inner and outer panels, respectively. In order to optimize the design of the inner panel, the stamping process was analyzed with the finite element method (FEM). Laser welding by CW Nd:YAG were used to join the magnesium alloy sheets. Based on the simulation results and mechanical test results of the joints, the determination of die design variables and their influence on formability were discussed. Furthermore, a prototype based on the proposed design was manufactured and the static stiffness test was carried out. The results demonstrate the feasibility of the proposed hybrid hood with a weight reduction of 25.7%.