• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.2
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• pp.175-181
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• 2007

The objective of this study was to develop formability evaluation techniques in order to apply aluminum sandwich panel for automotive body parts. For this purpose, newly adopting formability evaluation (using limit dome height and plane strain test) was carried out in order to secure the fundamental data for the measurement of sheet metal forming and the establishment of optimum forming conditions of the aluminum sandwich panel. The results showed that there were good agreements between the old formability evaluation method and the new method which was more simplified than that of old one. From the results of these formability evaluation, the formability of sandwich panel was higher than that of aluminum alloy sheet alone which was the skin component for the sandwich panel. Also, it was found that sandwich panel could reduce the weight and could have the same flexural rigidity simultaneously when it was compared to the automotive steel sheet.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.6
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• pp.709-715
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• 2016

This paper presents a comparison of an experimental study on spot and plug welding of an automotive body panel. Spot welding is a common joining technology used in automotive body panel assembly. In automotive body repair, however, plug welding is widely used due to its technical simplicity and cost benefit. Some researchers have focused on the use of spot welding in the manufacturing process, but there has been very little research done with respect to the engineering analysis of the plug welding process. In this study, two kinds of specimens are considered to compare the difference of failure strength between spot weld and plug weld: normal tension and shear tension. The experimental results show, in both normal tension and shear tension, that spot welding has higher failure strength than plug welding. In addition, plug welding is more vulnerable to shear tension than normal tension. This study can be applied to further studies on practical optimization for maintenance and repair of automotive body panels.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.248-255
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• 2015

The warm drawing of magnesium alloy AZ31B sheet is affected by temperature because tensile elongation is changed due to the elevated temperature. In the current study, the effect of temperature was investigated for an automotive dash panel part by both experimental and FE analysis. Tensile tests were performed to obtain mechanical properties for various temperatures. AZ31B alloy sheet shows increased total elongation with increasing deformation temperature in the range of 200 to 300℃. The heating channel inserted into the die was used to regulate and to obtain an optimal temperature. A temperature controller was constructed to reduce temperature variation. Warm drawing of magnesium alloy AZ31B was performed to produce the desired shape of the lightweight automotive dash panel. The simulated results showed good agreement with the experimental results.

• Transactions of Materials Processing
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• v.24 no.2
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• pp.107-114
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• 2015

The current study presents a geometric measurement and analysis of the section profile for a feature line surface on an automotive outer panel. A feature line surface is the geometry which is a visually noticeable creased line on a smooth panel. In the current study the section profile of a feature line surface is analyzed geometrically. The section profile on the real press panel was measured using a coordinate measuring machine. The section profiles from the CAD model and the real panel are aligned using the same coordinate system defined by two holes near the feature line. In the aligned section profiles the chord length and height of the curved part were measured and analyzed. The results show that the feature line surface on the real panel is doubled in width size.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.2
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• pp.260-266
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• 2010

Today's consumers are looking for emotional design which can fulfill their own potential desire. Emotion varies according to individual circumstance, age, sex, culture, education, profession and so on. Automotive instrument panel design is the most important part of interior design, because it affects the impression of interior design and has the equipments for safety, entertainment and various information. Thus, this study was performed to apply emotional design to automotive instrument panel which is the most important part of automotive interior, and find the best bonding conditions to build instrument panel efficiently by comparing mechanical properties in thermoplastic resin of polyethylene (PE) adhesion. Satisfactory adhesion was executed in ultrasonic welding for the same materials of PE. The best welding conditions were found to be welding time of I second, welding pressure of 250 kPA for PE-PE welding. Dissimilar materials were adhered when adhesion and ultrasonic welding were performed at the same time.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.7
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• pp.700-705
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• 2009

In order to enhance the dynamic stiffness of automotive panel, effect of bead and curved surface was investigated. Modal test was performed for principle specimens which have various kinds of beads, holes and curved surfaces. Test was also performed for conventional dash panel assembly and rear floor panel assembly and curved shaped ones. Results showed that curved shape increased the natural frequency of automotive panel more effectively than the bead. Finite element analysis was also performed and yielded good match with the test results.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.8
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• pp.1472-1479
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• 2002

In order to improve automotive fuel economy, vehicle weight should be reduced. Achieving significant weight reductions will normally require reducing the panel thickness or using alternative materials such as aluminum alloy sheet. These changes will affect the dent resistance of the panel. In this study, the correlation between panel size, curvature, thickness, material properties and dent resistance is investigated. A parametric approach is adopted, utilizing a "design software" tool incorporating empirical equations to predict denting and panel stiffness for simplified panels. The most effective period to optimize an automotive body panel is early in its development. The developed design program can be used to minimize panel thickness or compare different materials, while maintaining adequate panel performance.

• Journal of Mechanical Science and Technology
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• v.16 no.12
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• pp.1673-1686
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• 2002

In the interest of improved automotive fuel economy, one solution is reducing vehicle weight. Achieving significant weight reductions will normally require reducing the panel thickness or using alternative materials such as aluminum alloy sheet. These changes will affect the dent resistance of the panel. In this study, the correlation between panel size, curvature, thickness, material properties and dent resistance is investigated. A parametric approach is adopted, utilizing a "design software" tool incorporating empirical equations to predict denting and panel stiffness for simplified panels. The most effective time to optimize an automotive body panel is early in its development. The developed design program can be used to minimize panel thickness or compare different materials, while maintaining adequate panel performance.

• Korean Journal of Computational Design and Engineering
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• v.18 no.2
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• pp.113-119
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• 2013

This paper proposes an approach to detect unintended deflections in an automotive outer panel. Conventionally, the detection of unintended deflections has been performed by experienced works, and it requires much amount of time and efforts. The motivation of this work is to reduce such efforts by providing an automated detection methodology. For the detection of unintended deflections, we make use of the measured data from an optical scanner which can be considered as a Z-map data. The proposed approach consists of four major steps; 1) measured data acquisition for an automotive outer panel, 2) identification of shape features, 3) removal of shape features, and 4) detection of unintended deflections via curvature analysis.

• International Journal of Automotive Technology
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• v.6 no.3
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• pp.277-283
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• 2005

Formability simulation of automotive panels at early design phases can reduce product and tooling development time and cost. However, for the simulation to be effective in leading the design process, fast and reliable results should be achieved with limited design definition and minimum modeling effort. In this paper, nonlinear finite element analysis is used to develop an automated process for the formability simulation of automotive body panels at early design phases. Due to the limited design definition at early design phases, the automated simulation process is based on the plane strain analysis for selected number of typical sections along the panel. Therefore, an entire panel can be analyzed with few sections. The state of plane strain can be easily induced, during simulation through symmetry and applied boundary conditions that simplify the modeling process. To study the reliability and effectiveness of the developed simulation process, the analytical results are compared with measured results of production automotive body side panels. The comparison demonstrates that the developed simulation process is reliable and can be effective for analyzing sheet metal formability, in early vehicle development phases.