• Journal of Power System Engineering
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• v.18 no.1
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• pp.84-90
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• 2014

The high pressure hoses are widely used for the vehicles, aircraft, and overall industries. The hose assembly is generally composed of a nipple, a socket and a hose with reinforcement layers to increase the tensile strength. To produce the hose assembly, crimping or swaging process is usually used to clamp its components to ensure the prevention of fluid leakage. Crimping is a cold-working technique to form a strong bond between the workpiece and a non-metallic component. The crimping stroke is a primary parameter to be determined in the metalworking process, and it plays an important role in hose performance. This study aims at investigating the optimal crimping stroke according to the size of aircraft high pressure hose by using MSC/MARC. It is supposed that the results can be useful to get the information about the crimping stroke in manufacturing process, even with the different size of a hose.

• Journal of Welding and Joining
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• v.27 no.1
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• pp.79-84
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• 2009

Ferritic stainless steel, which has been used as material for decoration parts in automobile, is recently used as material for the exhaust system due to its good performance at high temperature. To improve the fuel efficiency and purify automotive exhaust gas, it is needed to increase the temperature of exhaust gas. However, it is frequently reported that the rising of the temperature of exhaust gas increases thermal stress at exhaust manifold, which results in thermal fatigue failure in welded joints. Therefore, in this study, effects of chemical composition of steel and welding parameters on thermal fatigue properties of synthetic heat affected zone in ferritic stainless steel have been investigated. It has been found that thermal fatigue life in heat affected zone is affected by bead shape of welded joint and amount of soluble Nb in steel. Especially, Nb-Ti added steel has higher thermal fatigue life in comparison to Nb added steel, which is attributed to difference of precipitation behavior in both steels.

• Journal of Welding and Joining
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• v.32 no.5
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• pp.65-71
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• 2014

Atmospheric plasma spraying (APS) is world-widely used process in the automotive industry as a method to provide wear resistance coatings for engine cylinder bore, using various materials. The weight of engine blocks can be considerably decreased by removing cast iron liners, which can finally result in the improvement of fuel efficiency. In this study, five kinds of powder materials, 1.2C steel powder and 1.2C steel powder mixed with 5, 10, 15, 20 wt.%. molybdenum powder, were deposited by atmospheric plasma spraying in order to investigate the effect of molybdenum on the wear resistance of coatings. Microstructural analysis showed that molybdenum splats were well distributed in 1.2C steel matrix with intimate bonding. The molybdenum added coatings showed better tribological properties than 1.2C steel coating. However, above the 15 wt.%. blending fraction, wear resistance was somewhat degraded with poor roughness of worn surface due to the brittle fracture occurred in molybdenum splats. Consequently, compared to conventional liner material, gray cast iron, 10 wt. pct. molybdenum blended 1.2C steel coating showed much better tribological properties and therefore it looks very feasible to replace gray cast iron liner.

• Journal of Hydrogen and New Energy
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• v.20 no.1
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• pp.1-8
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• 2009

Hydrogen production by the reaction of aluminum alloys and NaOH solution was studied for an automotive proton exchange membrane fuel cell(PEMFC) application. In our experiment conditions($30{\sim}75^{\circ}C$, NaOH $0.5{\sim}5M$), passivation of aluminum was not occurred. Higher rate of hydrogen production was observed at the reaction with Al alloys that contain impurities. With an increase in reaction temperature, hydrogen production rate by an increase in NaOH concentration increased much. When hydrogen was fed into the anode without filtering, PEMFC cell performance decreased 35% by ionic contamination such as $Na^+$ on the membrane and electrode. Thus, filtering of produced hydrogen is necessary for PEMFC operation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.4
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• pp.69-75
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• 2009

Recently developed automotive components are getting lighter providing a higher fuel efficiency and performance. Following the current trend, this study proposes a structural optimization method for the lower control arm installed at the front side of a Vehicle. Lightweight design of lower control arm can be achieved through design and material technology. In this research, the shape of lower control arm was determined by applying the optimization technology and aluminum was selected as a steel-substitute material. Strength performance is the most important design requirement in the structural design of a control arm. This study considers the static strength in the optimization process. For the optimum design, the durability analysis is performed to predict its fatigue life. In this study, the kriging interpolation method is adopted to obtain the minimum weight satisfying the strength constraint. Optimum designs are obtained by the in-house program, EXCEL-Kriging. Also, based on the optimum model obtained for the static strength, the optimization of Index of Fatigue Durability is carried out to get th optimum fatigue performance.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.5
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• pp.63-68
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• 2010

The use of aluminum alloy parts in the automotive industry has been increasing recently due to its low weight compared with steel to improve fuel efficiency. Companies in the auto parts' manufacturing sector are expected to meet the government's strict environmental regulations. In this study, manufacturing process of aluminum alloy bolt has been designed from forming to heat treatment. Bolt forming process is composed of cold forging for body and rolling for thread. In this study only cold forging process is considered by employing the finite element method. In the cold forging process, preform shape was designed and damage value was considered for die design. Two steps of forging process has been developed by the simulation and a prototype was manugactured accordingly. As a final process, solution heat treatment and aging process was employed. A final prototype was found to meet the required specifications of tensile strength and dimension.

• Tribology and Lubricants
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• v.32 no.5
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• pp.166-171
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• 2016

Electric vehicle ownership is expanding for two reasons: its technology features have enhanced fuel economy, and the number of vehicle emissions regulations is increasing. Battery performance has a large influence on the capability of electric vehicles, and even though battery thermal management has been actively researched, specific technological improvements to battery performance are not being presented. For instance, many industrial applications utilize vortex tubes as components for refrigeration machines because of their numerous intrinsic benefits. If electric vehicles incorporate vortex tubes for battery cooling, performance and efficiency advancements are possible. This study uses a counter-flow vortex tube to investigate its temperature separation characteristics, based on the back pressure of the cold air exit and the difference between the inlet and back pressures. The experiment uses a vortex tube with the following parameters: six nozzle holes, a 20 mm inner vortex diameter (D), a 14D tube length, a 0.7D cold exit orifice diameter, and a nozzle area ratio of 0.142. The measurements prove that the temperature difference between the hot air and cold air decreased because of the flow resistance of the hot air and the backflow phenomenon at the cold air exit. The flow resistance causes the temperature difference to decrease, and the back pressure of the cold air exit influences the flow resistance. The results show that the back pressure significantly influences the efficiency of temperature separation.

• Transactions of Materials Processing
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• v.26 no.6
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• pp.348-355
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• 2017

In recent years, dissimilar materials such as aluminum, magnesium, titanium, and advanced high strength steel are widely used in automotive body due to environment concerns and fuel consumption. Therefore, joining technology is important for assembling components made of dissimilar materials. In this study, friction stir hole clinching (FSHC) was proposed as a new mechanical joining method to join dissimilar materials. This process stirs and heats the upper sheet, forming mechanical interlocking with the lower sheet. The feasibility of this FSHC process was verified by comparing cross-section of joint in FSHC and hole clinching process under the same processing condition. Taguchi method was also applied to the FSHC process to estimate the effect of process parameters on joint strength and obtain optimal combination of process parameters. Joint strength of FSHC with optimal process condition was compared to that of FSHC with initial process condition as well as that of hole clinching with optimal process condition. Results showed that the FSHC process was useful for joining dissimilar materials, even if the formability of materials was low.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.5 s.182
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• pp.51-58
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• 2006

The necessities for heightening fuel efficiency as well as lightweight design, lead to an increase of the use of aluminum alloys in the automobile industry. Extruded aluminum profile channels are used widely for the design of frame parts as lightweight assemblies, especially if a high stiffness is needed. While many applications can be realized with forming of hollow square-sectioned extruded profiles such as a stretch bending and a hydro-forming, some applications demand the use of a press bending which can be hardly found in the previous study. In this study, by introducing the use of a press bending into car sub-frames, the demands for higher accuracy as well as higher flexible method than the conventional methods will be satisfied. With respect to the design of sub-frames, the process planning was performed from the shape of a sub-frame product. The designed processes were analyzed by the commercial FEM code, DEFORM-3D. Forming dies for the each process were designed and prototypes of sub-frames were manufactured by the verified farming process. In addition, some of the important features of design parameters in the press bending were reviewed.

• Transactions of Materials Processing
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• v.26 no.4
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• pp.222-227
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• 2017

In order to respond to environmental regulations and increased demand for fuel economy, the demand for lightweight car bodies has grown. Hydroforming of aluminum is one possible solution as it eliminates the need for additional welding to develop closed cross-sectional parts. However, the low formability of aluminum is a limitation of its application. On the other hand, the ductility of materials can be improved at higher temperatures, and hot metal gas forming has been widely applied in the production of lightweight vehicle parts. In this study, aluminum alloy for pipe extrusion was developed by controlling the Mg:Cr:Mn ratio based on AA5083. Mechanical properties of the developed material were examined by tensile test and were applied to a forming simulation. Cold forming simulation for preforming and non-isothermal hot forming simulation for hot metal gas forming were carried out to validate process conditions. A prototype of the sidemember was manufactured under the given process condition. Finally, thickness distribution was compared with finite element analysis results.