• Transactions of Materials Processing
• /
• v.30 no.2
• /
• pp.61-68
• /
• 2021

As part of efforts to reduce the weight of automotive body-in-white, a hybrid center pillar with high strength 7075 aluminum alloy (AA7075) sheet and carbon fiber reinforced plastic (CFRP) has been recently studied. In the fabrication of the AA7075-CFRP hybrid center pillar, the AA7075 sheet might go through heating-forming-in-die quenching (HFQ), artificial aging, hybridizing, and then paint baking processes. In this study, we investigate the effects of the heat treatment history associated with each process on the tensile strength of the AA7075 sheet. Typical heat treatment conditions are HFQ for 20 minutes at 480℃ and then cooling down with die, artificial aging of T6 temper for 24 hours at 120℃, hybridizing for 10 minutes at 150℃, and paint baking for 20 minutes at 180℃. The tensile strength of the AA7075 sheet is continuously increased by a series of heat treatments of hybridizing and paint baking and is expected to have yield stress above 500MPa without artificial aging of T6 temper.

• Journal of Welding and Joining
• /
• v.30 no.3
• /
• pp.66-70
• /
• 2012

Welding is an essential process in the automotive industry. Most welding processes that are used for auto body is spot welding. And $CO_2$ arc welding is used in a small part. In production field, $CO_2$ arc welding process is decreased and spot welding process is increased due to welding quality is poor and defects are occurred in $CO_2$ arc welding process frequently. But $CO_2$ arc welding process should be used at robot interference parts and closed parts where spot welding couldn't. $CO_2$ welding is divided into lap welding and plug arc spot welding. In case of plug arc spot welding, burn through and under fill were caused in various welding environment such as different thickness combinations of base metal, teaching point, over the two steps welding and inconsistent voltage/current. It makes some problem like poor quality of welding area and decrease the productivity. In this study, we will evaluate the effect of teaching point through the weld pool behavior and bead geometry in the arc spot welding at the plut hole. Welding position is horizontal position. And galvanized steel sheet of 2.0mm thickness that has plug hole of 6mm diameter was used. Teaching point was changed by center, top, bottom, left and right of the plug hole. At each condition, the phenomenon of weld pool behavior was confirmed using a high-speed camera. As the result, we find the center of plug hole is the most optimal teaching point. In the other teaching point, under fill was occurred at the plug hole. This phenomenon is caused by gravity and surface tension. For performance of arc spot welding at the plug hole, the teaching condition should be controlled at a center of plug hole.

• Design & Manufacturing
• /
• v.14 no.4
• /
• pp.65-70
• /
• 2020

Partial reinforcement of sheet metal parts with CFRP patch is a technology that can realize ultra-lightweight body parts while overcoming the high material cost of carbon fiber. Performing these patchworks with highly productive press equipment solves another issue of CFRP: high process costs. The A-pillar is the main body part and has an undercut shape for fastening with other parts such as roof panels and doors. Therefore, it is difficult to bond CFRP patches to the A-pillar with a general press forming tool. In this paper, a flexible system that applies uniform pressure to complex shapes using ceramic particles and silicone rubber is proposed. By benchmarking various A-pillars, a reference model with an undercut shape was designed, and the system was configured to realize a uniform pressure distribution in the model. The ceramic spherical particles failed to realize the uniform distribution of high pressure due to their high hardness and point contact characteristics, which caused damage to the CFRP patch. Compression equipment made of silicone rubber was able to achieve the required pressure level for curing the epoxy. Non-adhesion defects between the metal and the CFRP patch were confirmed in the area where the bending deformation occurred. This defect could be eliminated by optimizing the process conditions suitable for the newly developed flexible system.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.17 no.1
• /
• pp.9-14
• /
• 2016

This study evaluated a digital locking device design using detection distance of 13.4mm of a human body sensing type magnetic field coil. In contrast to digital locking devices that are used nowadays, the existing serial number entering buttons, lighting, number cover, corresponding pcb, exterior case, and data delivery cables have been deleted and are only composed of control ON/OFF power switches and emergency terminals. When the magnetic field coil substrates installed inside the inner case detects the electric resistance delivered from the opposite side of the 12mm interval exterior contacting the glass body part, the corresponding induced current flows. At this time, the magnetic field coil takes the role as a sensor when coil frequency of the circular coil is transformed. The magnetic coil as a sensor detects a change in the oscillation frequency output before and after the body is detected. This is then amplified to larger than 2,000%, transformed into digital signals, and delivered to exclusive software to compare and search for embedded data. The detection time followed by the touch area of the body standard to a $12.8{\emptyset}$ magnetic field coil was 30% contrast at 0.08sec and 80% contrast at 0.03sec, in which the detection distance was 13.4mm, showing the best level.

• Journal of the Korea Convergence Society
• /
• v.5 no.2
• /
• pp.13-18
• /
• 2014

In this study, two models due to the configuration of ripper at excavator are investigated by structural and fatigue analyses. The maximum stress and deformation are happened at the axis connected with the body of working device and the direct working part respectively. Model 1 is thought to have more structural durability than model 2. Fatigue life or damage in case of 'SAE bracket history' whose load change is most severest among non-uniform fatigue loads is shown to become most unstable. But life or damage in case of 'Sample history' whose load change is slowest among non-uniform fatigue loads is shown to become most stable. These study results can be effectively utilized with the design of ripper at excavator by anticipating and investigating prevention and durability against its fatigue damage.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.22 no.4
• /
• pp.635-642
• /
• 2013

We have prepared a DEMO conveyor device for conveying a large 8G class glass sheet using ahorizontal air-cushion system. This device consists of the body frame and the driving frame that are combined to realize a frame for conveying glass without any contact.The driving frame comprises an air flotation table (bed), drive roller supported at both ends, and ASU. Part of the ASU serves to control the airflow as the chamber consists of a porous pad and fan. Fiber filters replace the porous pad and axial fans serve as an air compressor. In addition, to determine the appropriate glass levitation from the air table, this study examined the design specifications of the applied filter (discharge speed of HEPA and ULPA filters, and flow rate) as well as the height of the and the proper supporting roller height (14mm). Then, after adjusting the position of the ASU and the number of ASUs required to configure the UNIT air floating C/V, we analyzed the height and flatness of the glass and derived the appropriate layout (1140-mm distance between ASUs).

• Journal of the Korea Convergence Society
• /
• v.10 no.7
• /
• pp.149-154
• /
• 2019

This paper is to study the durability through structural analysis on the front undercover of SUV car for offroad. It was investigated which model became structurally best by analyzing three kinds of models which are similar to the configuration of undercover for the protection of the part under car body which has been used really. The models of undercover were designed through CATIA program and analyzed by using ANSYS program as three kinds of models A, B and C. Through the analysis results, model B was expressed to have the best durability as model B has the least equivalent stress and the longest fatigue life among three models. As the design data with the durability of undercover obtained on the basis of this study result are utilized, the esthetic sense can be shown by being grafted onto the machine or structure at real life.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.19 no.3
• /
• pp.52-60
• /
• 2018

In the automobile industry, in order to increase the fuel efficiency and conform to the safety regulations, it is necessary to make the vehicles as light as possible. Therefore, it is crucial to manufacture dual phase steels, complex phases steels, MS steels, TRIP steels, and TWIP from high strength steels with a tensile strength of 700Mpa or more. In order to apply ultra-high tensile strength steel to the body, the welding process is essential. Resistance spot welding, which is advantageous in terms of its cost, is used in more than 80% of cases in body welding. It is generally accepted that ultra-high tensile strength steel has poor weldability, because its alloy element content is increased to improve its strength. In the case of the resistance spot welding of ultra-high tensile steel, it has been reported that the proper welding condition area is reduced and interfacial fracture and partial interfacial fracture occur in the weld zone. Therefore, research into the welding quality judgment that can predict the defect and quality in real time is being actively conducted. In this study, the dynamic resistance of the weld was monitored using the secondary circuit process variables detected during resistance spot welding, and the factors necessary for the determination of the welding quality were extracted from the dynamic resistance pattern. The correlations between the extracted factors and the weld quality were analyzed and a regression analysis was carried out using highly correlated pendulums. Based on this research, a regression model that can be applied to the field was proposed.

• Proceedings of the Korean Powder Metallurgy Institute Conference
• /
• 2000.04a
• /
• pp.9-10
• /
• 2000

An important business-field of world-wide steel-industry is the coating of thin metal-sheets with zinc, zinc-aluminum and aluminum based materials. These products mostly go into automotive industry. in particular for the car-body. into building and construction industry as well as household appliances. Due to mass-production, the processing is done in large continuously operating plants where the mostly cold-rolled metal-strip as the substrate is handled in coils up to 40 tons unwind before and rolled up again after passing the processing plant which includes cleaning, annealing, hot-dip galvanizing / aluminizing and chemical treatment. In the liquid Zn, Zn-AI, AI-Zn and AI-Si bathes a combined action of corrosion and wear under high temperature and high stress onto the transfer components (rolls) accounts for major economic losses. Most critical here are the bearing systems of these rolls operating in the liquid system. Rolls in liquid system can not be avoided as they are needed to transfer the steel-strip into and out of the crucible. Since several years, ceramic roller bearings are tested here [1.2], however, in particular due to uncontrollable Slag-impurities within the hot bath [3], slide bearings are still expected to be of a higher potential [4]. The today's state of the art is the application of slide bearings based on Stellite\ulcorneragainst Stellite which is in general a 50-60 wt% Co-matrix with incorporated Cr- and W-carbides and other composites. Indeed Stellite is used as the bearing-material as of it's chemical properties (does not go into solution), the physical properties in particular with poor lubricating properties are not satisfying at all. To increase the Sliding behavior in the bearing system, about 0.15-0.2 wt% of lead has been added into the hot-bath in the past. Due to environmental regulations. this had to be reduced dramatically_ This together with the heavily increasing production rates expressed by increased velocity of the substrate-steel-band up to 200 m/min and increased tractate power up to 10 tons in modern plants. leads to life times of the bearings of a few up to several days only. To improve this situation. the Mechanical Alloying (MA) TeChnique [5.6.7.8] is used to prOduce advanced Stellite-based bearing materials. A lubricating phase is introduced into Stellite-powder-material by MA, the composite-powder-particles are coated by High Energy Milling (HEM) in order to produce bearing-bushes of approximately 12 kg by Sintering, Liquid Phase Sintering (LPS) and Hot Isostatic Pressing (HIP). The chemical and physical behavior of samples as well as the bearing systems in the hot galvanizing / aluminizing plant are discussed. DependenCies like lubricant material and composite, LPS-binder and composite, particle shape and PM-route with respect to achievable density. (temperature--) shock-reSistibility and corrosive-wear behavior will be described. The materials are characterized by particle size analysis (laser diffraction), scanning electron microscopy and X-ray diffraction. corrosive-wear behavior is determined using a special cylinder-in-bush apparatus (CIBA) as well as field-test in real production condition. Part I of this work describes the initial testing phase where different sample materials are produced, characterized, consolidated and tested in the CIBA under a common AI-Zn-system. The results are discussed and the material-system for the large components to be produced for the field test in real production condition is decided. Outlook: Part II of this work will describe the field test in a hot-dip-galvanizing/aluminizing plant of the mechanically alloyed bearing bushes under aluminum-rich liquid metal. Alter testing, the bushes will be characterized and obtained results with respect to wear. expected lifetime, surface roughness and infiltration will be discussed. Part III of this project will describe a second initial testing phase where the won results of part 1+11 will be transferred to the AI-Si system. Part IV of this project will describe the field test in a hot-dip-aluminizing plant of the mechanically alloyed bearing bushes under aluminum liquid metal. After testing. the bushes will be characterized and obtained results with respect to wear. expected lifetime, surface roughness and infiltration will be discussed.

• Journal of Preventive Medicine and Public Health
• /
• v.32 no.1
• /
• pp.48-59
• /
• 1999

Objectives. This study was conducted to evaluate the association between upper extremity musculoskeletal symptoms and Rapid Upper Limb Assessment(RULA) in vehicle assembly line workers. The goal of this study is to show the feasibility of RULA as a checklist for work related musculoskeletal symptoms (WMSDs) in Korean workers. Methods. The total number of 199 people from the department of assembly and 115 people from the department of Quality Control(QC) in automotive plant were subjects for this cross sectional study. A standard symptom questionnaire survey has been used for the individual characteristics, work history, musculosketal symptoms and non-occupational covariates. The data were obtained by applying one-on-one interview for the all subjects. RULA has been applied for ergonomic work posture analysis and the primary ergonomic risk sure was computed by RULA method. Association between upper extremity musculoskeletal symptoms and RULA were assessed by multiple logistic regression analysis. Results. A total of 314 workers was examined. The prevalence of musculoskeletal symptoms by NIOSH case definition was 62.4%. The distribution of musculoskeletal symptoms by the part of the body turned out to be following; back:41.4%, neck: 32.8%, shoulder: 26.4%, arm: 10.5% and hand:29.3%. The relationship of the individual RULA scores were statistically significant for the prevalence of musculoskeletal symptoms. As the result of the multiple logistic regressioin analysis, grand final score (OR=2.250 95% CI: 1.402-3.612) was associated with musculoskeletal symptoms in any part of the body.; upper arm score(OR=1.786 95% CI: 1.036-3.079) and posture score A(OR=1.634 95% CI: 1.016-2.626) in neck; muscel use score(OR=3.076 95% CI:1.782-5.310) and posture score A(OR=1.798 95% CI: 1.072-3.017) in shoulder; upper arm score(OR=1.715 95% CI: 1.083-2.715) and muscel use score(OR=2.057 95% CI:1.303-3.248) in neck & shoulder; muscle use score(OR=10.662 95% CI: 3.180-35.742) in arm; writst/wist score(OR=2.068 95% CI: 1.130-3.786) and muscle use score(OR=2.215 95% CI: 1.284-3.819) in hand & wrist.; muscle use score of trunk (OR=2.601 95% CI: 1.147-5.901) in back. Conclusions. Musculoskeletal symptoms of the extremities were strongly associated with individual RULA body score. These results show that RULA can be used as a useful assessment tool for the evaluation of musculoskeletal loading which is known to contribute to work-related musculoskeletal disorders. RULA also can be used as a screening tool or incorporated into a wider ergonomic assessment of epidemiological, physical, mental, environmental and organizational factors. As shown in this study, complement of the analysis system for the other risk factors and characterizing between the upper limb and back part will be needed for future work.