• 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.

• International Journal of Automotive Technology
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• v.8 no.1
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• pp.67-73
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• 2007

This study analyzes the interior noise that is generated during acceleration of a passenger car in terms of car body structure and panel contribution. According to the transfer method, interior noise is classified into structure-borne noise and air-borne noise. Structure-borne noise is generated when the engine's vibration energy, an excitation source, is transferred to the car body through the engine mount and the driving system and the panel of the car body vibrates. When structure-borne noise resonates in the acoustic cavity of the car interior, acute booming noise is generated. This study describes plans for improving the car body structure and the panel form through a cause analysis of frequency ranges where the sound pressure level of the rear seat relative to the front seat is high. To this end, an analysis of the correlation between body attachment stiffness and acoustic sensitivity as well as a panel sensitive component analysis were conducted through a structural sound field coupled analysis. Through this study, via research on improving the car body structure in terms of reducing rear seat noise, stable performance improvement and light weight design before the proto-car stage can be realized. Reduction of the development period and test car stage is also anticipated.

• Corrosion Science and Technology
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• v.2 no.5
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• pp.247-251
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• 2003

The corrosion forms of automotive body panels are various. One of the representations is a corrosion pitting and its propagation on the lapped portion by galvanic corrosion. But it has been difficult in correlation analysis about the corrosion propagation rate and mechanism of pitting and the actual automotive body in field. This present study interprets experimentally the rust pitting occurrence mechanism on the lapped panels through experimental methods. And field car investigation was executed for correlation analysis with experimental results. This paper compares corrosion propagation rate by pitting on hot-dip galvannealed steel sheets with corrosion forms in the automotive field condition. The research fundamentals which make it possible to predict the pitting occurrence and propagation on the lapped panels in the actual vehicles are given.

• 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.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.06a
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• pp.63-73
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• 1996

CAFE(기업평균연비) 규제의 적극적 대응책의 하나로 차체 경량화가 주목받고 있다. 이를 위해 사용되는 고분자 복합소재 중 특히 Exterior Body Panel에 많이 채택되고 있는 SMC(Sheet Molding Compound)에 대해 제조방법, 성형공정, 기술적 과제, 재활용, 적용 예 등을 살펴보았다. 1973년 GM의 Corvette로부터 본격적으로 사용되기 시작한 SMC는 미국, 유럽을 중심으로 사용량이 계속 증가되고 있으며, 자동화가 용이하고 성형Cycle이 짧아 타 열경화성 고분자복합재료 성형방법에 비해 대량생산에 유리하며, 도장 특성이 우수하며 자 동차 부품용으로 가장 보편적인 방식이다.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.33-40
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• 1998

In recent domestic automotive industry, 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, have been increased. 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 shortcomings of available sheet metal forming softwares in the market. 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 making 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 adopting the selected process in a real stamping die manufacturing facility.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.10
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• pp.115-126
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• 2004

In the present work a finite element formulation using dynamic-explicit time integration scheme is used for numerical analysis of auto-body panel stamping processes. The lumping scheme is employed for the diagonal mass matrix and dynamic explicit formulation. Analyzed auto-body panel stomping process correction of forming using software called Dynaform using dynamic extensive method. Further, the simulated results for the auto-body panel stamping processes are shown and discussed. Its application is being increased especially in the automotive industrial area for the cost reduction, weight saving, and improvement of strength.

• 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.