• Journal of Welding and Joining
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• v.33 no.2
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• pp.69-77
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• 2015

High strength steels have been continually being developed to improve in fuel economy in automotive and ensure safety of passengers. New bonding and welding methods have been required for improving weldability on high strength steels. In this study, resistance spot welding and Weld-bond with nugget diameters of 4.0mm, 5.0mm, 6.0mm and 7.0mm were produced and tested, respectively. In order to confirm the effect of nugget diameters on tensile shear characteristic of the Weld-bond, tensile shear characteristics of Weld-bond were compared with those of resistance spot welding and adhesive bonding. Peak load of Weld-bond were increased as the nugget diameter increases. After appearing maximum peak load continuous fracture followed with second peak owing to load being carried by resistance spot weldment. Fracture modes of the adhesive layer in Weld-bond fractures were represented by mixed fracture mode, which are cohesive failure on adhesive part and button failure at resistance spot welds. The results showed that the tensile shear properties can be improved by applying Weld-bond on TRIP steel, and more apparent with nugget diameter higher than 5${\surd}$t.

• Journal of Advanced Engineering and Technology
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• v.10 no.3
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• pp.285-290
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• 2017

Molding of body with ribs is the most difficult during flow molding process. The rib area is easy to be deformed at the rear side due to wall thickness variation. In this study, relationships between molding condition and deflection of rib-shaped part is investigated during the compression molding of fiber reinforced plastic composites, and the following results are derived. Polypropylene(PP), Polystyrene(PS), and stampable sheet(SS 40wt%) show the increment of deflection along with releasing temperature. For the correlation between incremental holding pressure load and deflection, stampable sheet exhibits lower deflection along with higher holding pressure, while PS shows significant increase of deflection with higher holding pressure, PP shows completely different characteristic, significant reduction of deflection along with higher holding pressure. Regarding to mold temperature and deflection, deflection amount of SS is the biggest, and PS shows the smallest. In addition, all three kinds shows the highest amount of deflection at 173C. Deflection is reduced when mold closing speed is increased. Amount of deflection in SS is larger and is not highly dependent on molding conditions like holding pressure and cooling parameters, compared with single component material like PP. This can be elucidated by anisotropic and inhomogeneous characteristics of glass fiber during filling process of stampable sheet composite.

• Laser Solutions
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• v.13 no.4
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• pp.14-20
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• 2010

Robot path generation and laser welding technology for manufacturing automotive body are studied. Laser welding and industrial robot systems are used with the robot based laser welding system. The laser system used in this study is 1.6kW Fiber laser, while the robot system is 6 axes Industrial robot (payload: 130kg). The robot based laser welding system is equipped with laser scanner system for remote laser welding. The laser source, robot and laser scanner system are used to increase the processing speed and to improve the process efficiency. The welding joints of steel plate are butt and lapped joints. The quality test of the laser welding are through the observation the shape of bead on plate and cross-section of welding part. The 3 dimensional laser welding for non-linear pipe welding line is performed. This paper introduces the robot based laser welding system to resolve the limited welding speed and accuracy of the conventional spot welding system.

• Transactions of Materials Processing
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• v.14 no.1 s.73
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• pp.21-28
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• 2005

This paper is concerned with the quantitative effect of design parameters on a stamped part of the auto-body. The considered parameters in this paper are the blank holding force, the draw-bead force, the blank size which greatly affect the metal flow during stamping. The indicators of formability selected in this paper are failures such as tearing, wrinkling and the amount of springback. The stamping process of the front side inner member is simulated using the finite element analysis changing the design parameters. The numerical results demonstrate that the blank holding force cannot control the local metal flow during forming although it controls the overall metal flow. The modification of the initial blank size considering the punch opening line ensures the local wrinkling and reduces the amount of springback after forming. The restraining force of draw-bead controls the metal flow in the local area and reduces the amount of excess metal. It is noted that the parametric study of design parameters such as blank holding force, the blank size and the draw-bead are very important in the process design of the complicated member.

• Journal of Drive and Control
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• v.16 no.4
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• pp.87-92
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• 2019

Rotary dampers are damping devices which provide high resistance to shaft rotation. Rotary dampers are being used in various areas to enable the gentle opening and closing of the rotation motion relative to home furniture, industry machinery and automotive parts. Rotary dampers can be installed directly at the rotating point of a various part and can achieve uniform, gentle movement which increases quality and value of products. And generally, the silicone fluid is used as the damping medium because of its stable viscous properties. The movement of these little decelerators can be achieved with a high viscosity of working fluid and throttles installed in the body of the rotary damper. The damping force can be achieved clockwise, anti-clockwise or in both directions according to the structure of the orifices or throttles. In this paper, the torque performances of the rotary damper containing air in the working fluid were studied. For this purpose, the torque characteristic of the rotary damper according to the variation of various operating conditions such as clearance of leakage, dimensions of groove orifice, content ratio of air, etc., were simulated with AMEsim software.

• Journal of Power System Engineering
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• v.17 no.1
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• pp.97-103
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• 2013

Press machine has advantages over other manufacturing machine which can produce large quantities of products in short time so it is widely used in lots of industrial sectors. To obtain the vehicle's weight lightening and rigidity of the body-frame by applying 'Hot stamping' technique is increasing in the automotive field. In this paper, to improve the irregular vibration arose by 800Ton hot stamping press, the research was continued. Bed, slide and main frame are the key part of working precision, so perform structural analysis was conducted, and based on the analyzing results, structural changes were done on the parts where structural deformation occurred.

• Proceedings of the KSME Conference
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• 2000.11a
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• pp.407-412
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• 2000

In this study, a research for process design in bending of structural frame of AA6061-T6 with rubber pad was conducted. In this process, the conventional lower die made of metal is replaced with a polyurethane pad, resulting in high flexibility during bending. Vulcanized polyurethane rubber with shore A hardness of 60 was used for the pad. Experiments on a newly developed bending machine were carried out by controlling the stroke of the roller and horizontal movement of roller pad lower die. From this, the relation between roller path and geometry of the materials bent was obtained for the process design of producing roof rail part of a passenger car and the experimental result was compared with the target profile. For more accurate process design, it is required to control the roller path interactively. Based on the experience in developing the prototype bending machine, it is construed that a fully automated bending system with rubber pad to produce various light-weight components for automotive body frames can be successfully developed.

• Transactions of Materials Processing
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• v.17 no.3
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• pp.218-224
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• 2008

A recent trend in automotive parts has been an integration of sub-assemblies with unified shapes. Tube structures also have been integrated to one body structure by using a near net shape forming instead of adopting welding. A cylindrical elastomer-forming process can be utilized to form a steel tube compressed in a radial direction. This process has some advantages compared to a hydro-forming or a swaging process in the viewpoint of a lower investment and a higher productivity. In order to predict a feasible specification of products within a work capability of the elastomer-forming equipment developed previously, effects of geometrical parameters of a tube on its shape accuracy are examined. Two characteristic parameters to account for the shape accuracy are chosen. One is the curvature radius at the corner part and the other is the straight ratio of the formed region. Careful examination of two parameters has led that the shape accuracy can be easily predicted by the regression equation obtained from the response surface method.

• Laser Solutions
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• v.11 no.4
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• pp.21-28
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• 2008

Remote Laser welding technology for manufacturing automotive body is studied. Laser welding and industrial robot systems are used for the robot based laser welding system. The laser system is used 1.6kW Fiber laser(YLR-1600) of IPG. The robot system is used HX130-02 of Hyundai Heavy Industry(payload : 130kg). The robot based laser welding system is equipped with laser scanner system for remote laser welding. The welding joints of steel plate and steel plate coated with zinc are butt and lapped joints. The quality test of the laser welding are through the observation the shape of bead on plate and cross-section of welding part. During past three years the laser system, 4kW Nd:YAG laser (HL4006D) of Trumpf was used and the robot system, IRB6400R of ABB (payload:120kg) was used. The new laser source, robot and laser scanner system are used to increase the processing speed and to improve the process efficiency. This paper introduces the robot based remote laser welding system to resolve the limited welding speed and accuracy of the conventional laser welding system.

• Journal of Welding and Joining
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• v.34 no.4
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• pp.48-54
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• 2016

The use of Zn coated steel has increased in the automotive industry due to its excellent corrosion resistance. Conventionally the BIW(body-in-white) structure and the hang-on parts have been made of Zn coated steel and more recently Zn coated steel began to be applied in the chassis parts. During gas metal arc (GMA) welding of the chassis part, lap fillet joint used to be adopted but spatter generation and porosities are most important concerns. In the industrial applications, an intentional joint gap was made to avoid the weld defects but it is not easy to control the size of joint gap. In this research, gas tungsten arc (GTA) is combined with GMA welding where GTA precedes GMA. As pulsed arc was adopted as GMA, GTA was oscillated along the longitudinal direction by pulsing GMA, but the arc oscillation did not disturb the molten droplet transfer of GMA welding. By increasing the distance between GTA and GMA, the length of weld pool increased and porosity could be reduced. Moreover porosity in the welds was fully removed when the distance between two arcs was 15 mm.