• International Journal of Precision Engineering and Manufacturing
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• v.9 no.3
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• pp.55-58
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• 2008

Hydroforming is a forming technology in which a steel tube is set in a die and formed to fit a specified shape by applying hydraulic pressure from inside the tube while also applying force in the tube axial direction (axial feed). In present study, the entire design process chain for an automotive cross-member was simulated and developed using hydroforming technology on high-strength steel. The part design stage required a feasibility study. The process was designed using computer-aided design techniques to confirm the actual hydroformability of the part in detail. The possibility of using hydroformable cross-member parts was examined using cross-sectional analyses, which were essential to ensure the formability of the tube material for each forming step, including pre-bending and hydroforming. The die design stage included all the components of a prototyping tool. Press interference was investigated in terms of geometry and thinning.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.3
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• pp.72-77
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• 2017

This paper focuses on the development of a supporting S/W tool for the automated design of an automotive press trim die. To define the die design process based on automation, we analyze the press die design process of the current industry and group repetitive works in the 3D modeling process. The proposed system consists of two modules, namely the template models of the trim steel parts and UI function for their auto-positioning. Four kinds of template models are developed to adapt to various situations and the rules of the interaction formula which are used for checking and correcting the directions of the datum point, datum curve, datum plane are implemented to eliminate errors. The system was developed using CATIA Knowledgeware, CAA(CATIA SDK) and Visual C++, in order for it to function as a plug-in module of CATIA V5, which is one of the major 3D CAD systems in the manufacturing industry. The developed system was tested by applying it to various panels of current automobiles and the results showed that it reduces the time-cost by 74% compared to the traditional method.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.6
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• pp.419-427
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• 2018

In case high strength steels are applied for press-formed automotive parts, it is very difficult to secure forming accuracy due to large springback compared to moderate strength steels. In this study, a repetitive step-wise forming analyses based on secant method was proposed as the die design method for mandrel(bending tool) for the 2-axis bending equipments. A bending die with circular mandrel was designed for the DP780 blow motor case of which diameter and thickness are 70.8mm and 2.0mm respectively. Forming tests were performed to verify the validity of established die design and the results were compared with that of conventional HGI(Hot galvanized iron steel) blow motor case. For additional improvement in forming accuracy, an elliptical mandrel was proposed and its validity was verified using forming analyses based on secant method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.12
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• pp.1663-1668
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• 2011

Surface hardening treatment is required to improve the wear-resistance of press die because severe abrasion of die occurs during the drawing process in which the forming of the automotive body is completed and during the trimming process in which the unnecessary parts are cut. In this study, experiments on the laser surface treatment of press die are performed. Specimens are heat-treated separately at certain plate and edge position by using a diode laser to carry out suitable surface hardening treatment to reduce the wear during the drawing and the trimming processes, and the proper conditions for heat treatment are found. Spheroidal and flake graphite cast iron specimens are used, and the heat treatment characteristics of the two materials are compared. From the results of the study, it is confirmed that the heat treatment characteristics differed depending on the materials.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1996.10a
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• pp.156-160
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• 1996

In this study of made Unloader is moving linear transfer system for mainly plastic working or forming of small electronic unit and other at press line. This machine for lading and unloading a workpiece has been installed in a press in order to load and unload a workpiece form a press die. Control method be used PLC. it took data of input from each sensor and send signal of output to actuator today we have a lot of problem at work of press line. most of press work be operated by human so they often hurted terreble accident by press machine. Because press working system in automotive factories are now changing over to a transfer press working system this Unloader will give more easily and speedy production and manpower saving less of pruduction cost high perfomance

• Laser Solutions
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• v.2 no.1
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• pp.61-67
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• 1999

This study introduces the new concept in the evaluation criteria of the $CO_2$ laser Tailored Blank weldability, The materials used are 0.7mm, 1.5mm thick low carbon automotive galvanized steels. Welding tests were conducted for both similar thickness(0.7mm-0.7mm, 1.5mm-1.5mm) and dissimilar thickness(0.7mm-1.5mm) cases. The criteria developed for optimum welding conditions were based on relationship between results of die press forming test, weld transverse tensile test Erichsen test and weld penetration measurements. Application of the developed criteria(fracture ratio, strength ratio and D/To) in obtaining optimum welding condition revealed that a weld which satisfied any of the criteria did not fracture during actual die press test.

• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.1
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• pp.45-50
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• 2011

Hot-Press-Forming (HPF), an advanced sheet metal forming method using stamping at a high temperature of about $900^{\circ}C$ and quenching in an internally cooled die set, is one of the most successful forming process in producing crash-resistant parts such as pillars and bumpers with complex shape, ultrahigh strength, and minimum springback. To optimize conditions of a forming quality in HPF process and secure a safe product without any failures, such as fractures and wrinkling, the simulations based on the coupled thermo-mechanical analysis for a hot-press-formed lower control arm are applied with Taguchi's orthogonal array experiment. Three factor variables - the friction coefficient, blank shape, and hole location for burring - are selected to be optimized. The most effective condition of a forming quality for a hot-press-formed lower control arm is suggested. The simulation results are confirmed with experimental ones.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.10 no.9
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• pp.2173-2178
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• 2009

The die technology of a high-efficiency induction motor is an important technology for manufacturing the core (iron core), which is the major part of a high-efficiency induction motor. It is also an essential technology in enhancing national competitiveness. In this study, the core of a high-efficiency induction motor was designed and manufactured as 2 prototype dies: one is for small-size, and the other is for large-size. They are then tested by attaching in press, the result are considered.

• Transactions of Materials Processing
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• v.17 no.5
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• pp.350-355
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• 2008

Currently, in the automotive industry, the efforts to reduce the manufacturing cost by changing the manufacturing process are continually performed. In this paper, we proposed a new manufacturing process, the roll bending process of a ring plate of automotive fuel tank instead of conventional press blanking process to reduce material loss and manufacturing cost. Finite element analysis was used to optimize the roll bending process to assure rectangular cross-section of the ring plate. Also, spring-back analysis after the roll bending process was performed and dimension of the bending die considering spring-back was analyzed. Finally, we verified a possibility for realization of the proposed method with prototypes.

• Journal of the Korean Society of Safety
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• v.26 no.4
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• pp.1-6
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• 2011

New methods for joining sheet of metal are being sought. One of the most promising methods is MPJ (mechanical press joining). It has been used in thin metal work because of its simple process and relative advantages over other methods, as it requires no fasteners such as bolts or rivets, consumes less energy than welding, and produces less ecological problems than adhesive methods. In this study, the joining process and static behavior of single overlap joints has been investigated. During fixed die type joining process for SPCC plates, the optimal applied punching force was found. The maximum tensile-shear strength of the specimen produced at the optimal punching force was 1.75 kN. The FEM analysis result on the tensile-shear specimen showed the maximum von-Mises stress of 373 MPa under the applied load of 1.7 kN, which is very close to the maximum tensile strength of the SPCC sheet(= 382 MPa). This suggests that the FEM analysis is capable of predicting the maximum tensile load of the joint.