• 한국자동차공학회논문집
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• 제25권1호
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• pp.35-41
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• 2017

The use of engineering plastics in automotive components is increasing with the trend towards improving the car strength and reducing weight. Among the different choices of materials, engineering plastic emerged as the necessary material for achieving lower costs, reduced weight and improved production efficiency. To produce the automotive parts, it is important to predict defect and validation of injection molding prior to design. Injection molding analysis and structural analysis are widely applied as a part of the design process when developing automotive parts. Injection molding analysis, in particular, involves a highly complicated mechanism that requires deep knowledge of polymer properties as well as an analytic approach different from that used for a general isotropic material when the molded material is used as a structural material. This is because the parts made of polymer have pre-stress factors such as intrinsic deformation and residual stress. The most important factors for injection molded plastic products are injection molding condition and cavity design, taking into account ease of molding, mass production and application. Despite optimal injection molding conditions and cavity design, however, glass fiber orientation is critically linked to strength reduction. The application of injection molding and structural coupled analysis provides a low-cost solution for product molding and structural validation, all prior to the actual molding. The purpose of this study involves the validation, pre-study, and solution of defect in injection-molded polymer automotive parts using the simulation software for injection molding and structural coupled analysis. Finally, this thesis provides validation of an injection molding and structural coupled analytic mechanism that can demonstrate the effect of glass fiber orientation on mechanical strength. Design improvement ideas for the injection molded product of PPS (Poly Phenylene Sulfide)+40% glass fiber are also suggested.

• 전기학회논문지
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• 제67권3호
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• pp.448-453
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• 2018

PV module protective film plays an important role in protecting the solar cell from external environment by anti-hydrolysis polyester, UV resistance and mechanical properties. The backsheet was manufactured by using Roll-to-Roll dry laminating process. The backsheet structure is composed of 3 layers, which are PE, PET, and Fluorine polymer films. In this study, we have experimented the variation of thermal conductivities depending on MgO inputs 10% to 25% in order to confirm the dependence of the module efficiencies. High thermal conductive backsheet can increase the module output power efficiency because the heat is dissipated by spreading out the internal heat. Long-term environment weatherability tests were conducted for confirming 25 year reliability in the field such as PCT, UV, and power efficiency degradations. As the evaluation result, high thermal conductivity can be effective for increase of power efficiency of solar panel by using thermal conductive MgO masterbatch.

• 한국자동차공학회논문집
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• 제22권5호
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• pp.91-101
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• 2014

In this study, we presented a timing verification method for a passenger car diesel engine management system (EMS) using measurement-based worst-case execution time (WCET) analysis. In order to cope with AUTOSAR-compliant software architecture, a development process model is proposed. In the process model, a runnable is regarded as a test unit and its temporal behavior (i.e. maximum observed execution time, MOET) is obtained along with on-target functionality evaluation results during online unit test. Furthermore, a cost-effective framework for online unit test is proposed. Because the runtime environment layer and the standard calibration environment are utilized to implement test interface, additional resource consumption of the target processor is minimized. Using the proposed development process model and unit test framework, the MOETs of 86 runnables for diesel EMS are obtained with 213 unit test cases. Using the obtained MOETs of runnables, the WCETs of tasks are estimated and the schedulability is evaluated. From the schedulability analysis results, the problems of the initially designed schedule table is recognized and it is fixed by redesigning of the runnable mapping and task offset. Through the various test scenarios, the proposed method is validated.

• 한국산학기술학회논문지
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• 제13권12호
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• pp.5764-5769
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• 2012

본청업체와 하청업체간의 관계는 본청업체의 압박으로 하청업체는 강한 종속감을 가지고 있다는 것은 여러 연구를 통해서 입증되어오고 있다. 이러한 관계의 대표적인 분야가 자동차산업이다. 하청업체의 본청업체에 대한 종속감은 여러 요인들이 있지만 특히 부족한 기술력을 들 수 있다. 이러한 연구 안에서 일반적으로 외국기업이 하청업체일 경우에도 같은 결과를 가지고 오는지에 대한 연구는 많지 않다. 본 논문의 연구목적은 외국기업이 하청업체이면서 본청업체가 한국기업인 경우에는 어떤 영향이 있는지, 그리고 그 요인 중에서 특히 R&D 센터를 한국에 소재하고 있는 경우에도 기존의 연구와 같은 결과를 가져오는지에 대한 분석이다. 제 2장에서는 이론적 배경으로서 본청업체와 하청업체간의 비즈니스 관계에 대한 일반적인 특징을 살펴보았다. 제 3장에서는 연구방법을 이어서 제 4장에서는 하청업체로서 대표적인 독일 보쉬 회사가 R&D센터를 한국에 주둔시킴으로써 본청업체와의 비즈니스 관계에 미치는 영향에 대해서 사례분석으로 다루었다. 마지막으로 제 5장에서는 한국정부에 주는 정책적 시사점 및 연구의 한계점을 제시하였다. 본 논문에서 사례분석을 통해서 살펴본 비즈니스 관계는 하청업체가 적극적인 R&D센터 활동을 통해서 본청업체와의 관계를 파트너관계로 발전시킬 수 있음을 볼 수 있었다.

• 한국자동차공학회논문집
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• 제22권6호
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• pp.104-112
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• 2014

Generally, numerical approaches of evaluation for vehicle seat comfort have been studied without considering time-dependent characteristics and the only seating moment have been considered in seat design. However, the comfort not only at the seating moment but also in the long-term should be evaluated because the passengers are sitting repeatedly on the seat to drive the vehicle for hours. So, the aim of this paper is to carry out a quantitative evaluation of the time-dependent mechanical characteristics of seat foams and to suggest a process for predicting the viscoelastic deformation of seat foam in response to long-term driving. To characterize the seat materials, uniaxial compression and tension tests were carried out for the seat foam and stress relaxation tests were performed for evaluating the viscoelastic behavior of the seat foam. A unit solid element model was used to verify the reliability of the material model with respect to the compression behavior of the seat foam. It is not straightforward to evaluate the time-dependent compression of foams using the explicit solver because the viscoelastic material model is limited. To use the explicit solver, the material model must be modified using stress-degradation data. Normalized stress relaxation moduli were added to the stress-strain curves obtained under static conditions to achieve a time-dependent set of stress-strain relations that were compatible with the implicit solver. There was good agreement between the analysis results and experimental data.

• Interaction and multiscale mechanics
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• 제6권2호
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• pp.257-270
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• 2013

The use of lightweight materials has been steadily increasing in the automotive industry, and presents new challenges to material joining. Among many joining processes, self-piercing riveting (SPR) is particularly promising for joining lightweight materials (such as aluminum alloys) and dissimilar materials (such as steel to Al, and metal to polymer). However, to establish a process window for optimal joint performance, it often requires a long trial-and-error testing of the SPR process. This is because current state of the art in numerical analysis still cannot effectively resolve the problems of severe material distortion and separation in the SPR simulation. This paper presents a coupled meshfree/finite element with a moving boundary algorithm to overcome these numerical difficulties. The simulation results are compared with physical measurements to demonstrate the effectiveness of the present method.

• Journal of Welding and Joining
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• 제34권4호
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• pp.40-47
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• 2016

The Zn coating on automotive galvanized steel sheets can improve corrosion resistance. However, the boiling temperature of Zn is lower than the melting temperature of steel and it causes well-known spatter and porosity problem. One of most prominent solutions is a pretreatment of Zn coating by an additional welding arc prior to the main welding process. In this research, GTA and GMA are selected as heat sources for pretreatment and main welding processes, respectively. The authors suggested three possible mechanisms to reduce weld defects by the GTA pretreatment: (1) Formation of gap between the sheets; (2) Evaporation of Zn layer; (3) Oxidation of Zn layer. Among them, Zn Oxidation is the most important mechanism to reduce weld defects in the GTA-GMA hybrid process.

• 동력기계공학회지
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• 제10권2호
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• pp.22-28
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• 2006

Computer simulation of the air flow over an automotive vehicle is now becoming a routine process in automotive industry to assess the aerodynamic characteristics of a medium-size vehicle such as $C_d\;and\;C_1$ and aslo to investigate the possibility of improving aerodynamic performance of the vehicle as a preliminary design for the production line. Mainly due to its contribution in saving time and cost in the development of new cars, computer simulation of the air flow over a vehicle is usually done well before a production car is introduced to the market and in gaining more and more attention as powerful computer resources are getting readily available nowadays. To aerodynamically design a car is mainly related with reducing a drag coefficient of car. A well designed car usually has a $C_d$ value in the range of $0.3{\sim}0.4$. It is understandable that automotive industry is rushing to reduce a drag coefficient as reducing even a small fraction of the $C_d$ value can have an enormous overall impact on many areas. Actually, the present research model was able to achieve a $C_d$ value in the range of $0.3{\sim}0.36$ for flow velocities of $60km/h{\sim}100km/h$ by strategically removing the possible factor hazardous to lower $C_d$ value. Prediction of the medium-size vehicle aerodynamics using CFD was performed when an actual car model was in the development stage and three-dimensional modeling was also performed to optimize it as the best model in terms of the best aerodynamic performance.

• 한국자동차공학회논문집
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• 제22권2호
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• pp.7-16
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• 2014

Vehicle industry is developing research for producing high quality injection molded product. The main objective of this study is providing information about hydraulic system for researchers who are involved in the other fields, not hydraulic field. Another objective is developing hydraulic circuit simulation model which analyzes the cause of several destabilizing elements related to quality of injection molded products. Injection molded product consists of a lot of hydraulic parts, and there are many nonlinear facts for dynamic behavior. So, we used 'SimulationX' which is specialized in hydraulic system for developing simulation model.

• Design & Manufacturing
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• 제16권3호
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• pp.28-33
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• 2022

The recent increasing application rate of advanced high-strength steel(AHSS) for automotive parts makes it difficult to ensure the durability of forming tools. Significant load and friction generated during the piercing process of AHSS increase the wear rate and the damage degree to dies. These harsh process conditions also yield product failures, such as dimensional inconsistency of pierced holes and insufficient quality of hole's sheared edge. This study analyzed the effect of punch wear on the sheared surface of pierced parts and the forming load during the piercing process. Wear-shaped punches showed approximately 20% higher piercing load than normal-shaped punches, and the rollover ratio of the sheared surface also increased. It is considered that the dull edge of wear-shaped punches does not penetrate directly into the material but shears after tensioning it in a piercing direction. In addition, wear-shaped punches experienced compressive load even after completing the piercing process during the down-stroke and tensile load during the up-stroke. This load variation is related to the smaller diameter piercing holes produced by wear-shaped punches compared to normal-shaped punches. Thus, we demonstrated the predictability of the wear level of dies through a comparative analysis of the piercing load pattern.