• Transactions of the Korean Society of Automotive Engineers
• /
• v.10 no.1
• /
• pp.125-132
• /
• 2002

Recently, ULSAB(Ultra Light Steel Auto Body) concept is getting more attention due to various benefits in automotive body design. One of the ULSAB efforts is making a door with TWB(Tailor Welded Blanks). In TWB, two or more patches of steel panels are welded together before stamping process. In this research, domains and thicknesses of the patches in a front door structure are determined by a series of optimization schemes composed of topology, size and shape optimization and DOE(Design of Experiments) scheme. A door is designed to have better performances compared to exiting structure considering static stiffness and natural frequency. The final design is discussed and compared to the existing design.

• Journal of the korean Society of Automotive Engineers
• /
• v.12 no.6
• /
• pp.48-59
• /
• 1990

A finite element program was developed using line elements for simulating the stretch/draw forming operation of an arbitrarily-shaped plane-strain section. An implicit, incremental, updated Lagrangian formulation is employed, introducing a minimum plastic work path assumption for each time step. Geometric and material nonlinearities are also considered within each time step. The finite element equation is based on the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshes without depending on the explicit spatial derivatives of tool surfaces. The membrane approximation is adopted under the plane stress assumption. The sheet material is assumed to obey a rigid-viscoplastic constitutive law. The developed program was tested in the die-tryout of typical automotive inner panels. In order to determine a single friction coefficient and boundary length, FEM results and measurements of thinning for a stretched section of final die were compared. After finding analysis parameters, the sheet forming operations of original and final die designs were simulated. Excellent agreement between measured and computed thickness strains was obtained and the developed program was able to identify die designs which were rejected during die tryout.

• International Journal of Automotive Technology
• /
• v.7 no.6
• /
• pp.721-728
• /
• 2006

This paper is concerned with development of digital assembly cell. Automotive industries, try to find out new welding technologies to replace the existing spot welding which is not appropriate anymore. Because of many advantages like good accessibility, welding quality and fast welding speed, laser welding seems the most appropriate solution for automobile manufactures. To apply this technology to welding of car body, experiments must be conducted according to material, geometry and layer in welding area. Based on the data of these experiments, the laser welding process and the quality of stitches are identified. And then, the comparison between the requirements of welding and the potential of equipments allows selecting the best equipments. By using the digital manufacturing, the configurations of laser welding cell are carried out. After all, the optimal laser welding cell is chosen by the evaluation of alternative cells with technical and organizational criteria.

• Corrosion Science and Technology
• /
• v.9 no.2
• /
• pp.74-80
• /
• 2010

For the purpose of applying a hot-dip Zn-6mass%Al-3mass%Mg alloy coated steel sheet (ZAM) to automotive body materials, a laboratory study of the general properties required for inner and outer panels of automotive bodies was performed. Even with only light coating weight, ZAM showed an excellent corrosion resistance in terms of both cosmetic and perforation corrosion compared to the currently used materials for automotive bodies, GI70 and GA45. In our study, it was confirmed that ZAM exhibits as good as or better properties than GI70 in terms of spot weldability and press formability. Furthermore, since the same corrosion resistance can be achieved with less coating weight by applying ZAM, laser weldability is better than GI and GA.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.5
• /
• pp.25-30
• /
• 2016

This study investigates the heat transfer due to a change in the shape of a radiator panel inside a computer. As with models of radiator panels, models have the same surface areas. As the gap between heat transfer surfaces in model 1 becomes wider than those in model 2, the heat transfer at model 1 becomes smoother than that of model 2. By comparing the cooling processes between models 1 and 2 with respect to natural convection, a maximum temperature of $47.432^{\circ}C$ at model 1 becomes lower than that of model 2, at $49.821^{\circ}C$. Within the radiator panel, model 1 has been shown to be more effective than model 2. Accordingly, these results can be effectively applied to the shape design of radiator panels to imbue them with smoother and faster heat transfer through the finite element method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2004.08a
• /
• pp.83-90
• /
• 2004

The drawbead is one of the most important factors in sheet metal forming for automotive parts. So clarifying the friction characteristics between sheets and drawbead is essential to improve the formability of sheet metal. Therefore in this study, drawbead friction test was performed at various panels(cold rolled steel sheets, galvanized steel sheets, electrogalvanized coating steel sheets, electrogalvanized Zn-Fe alloy steel sheets and aluminum alloy steel sheets). Circular shape bead has been used for the test. The results show that friction and drawing characteristics were mainly influenced by the nature of zinc coating.

• Transactions of Materials Processing
• /
• v.14 no.6 s.78
• /
• pp.533-540
• /
• 2005

The hemming process, composed of flanging, pre-hemming and main hemming, is the last one of a series of forming processes conducted on the automotive panels, having greater influence on the outward appearance of cars rather than on their performance. The hem quality can be quantitatively defined by the hemming defects including turn-down/up, warp and roll-in/out. However, it is difficult to evaluate and predict the hem quality through an experimental measurement or a numerical calculation since the size of defects is very small. This study aims to precisely evaluate the hemming defects, especially turn-down and roll-in, through numerical and experimental approaches and to investigate the influence of process parameters on the hem quality, focused on how to simulate the same conditions as in the experiment by the finite element analysis (FEA). The FEA results on the turn-down and roll-in obtained from a model composed of the optimum-sized elements, including a spring element linked to the flanging pad, and given the double master contact condition between the inner and outer panels, had a good correlation with the experimental data. It is thought possible to make an early estimate of the hem quality in a practical automotive design by applying the methodology proposed in this study.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.20 no.9
• /
• pp.84-89
• /
• 2021

Indium tin oxide (ITO) transparent electrodes, which are used to manufacture organic light-emitting diodes, are used in light-emitting surface electrodes of display EL panels such as cell phones and TVs, liquid crystal panels, transparent switches, and plane heating elements. ITO is a major component that consists of indium and tin and is advantageous in terms of obtaining sheet resistance and light transmittance in a thin film. However, the optical performance of devices decreases with an increase in its thickness. A digital holography system was constructed and measured for the step measurement of the ITO thin film, and the reliability of the technique was verified by comparing the FE-SEM measurement results. The error rate of the step difference measurement was within ±5%. This result demonstrated that this technique is useful for applications in advanced MEMS and NEMS industrial fields.

• Transactions of Materials Processing
• /
• v.15 no.5 s.86
• /
• pp.387-394
• /
• 2006

In order to see the effect of die deformation on the forming analysis of sheet metals, the draw-ins, strains, and spring-backs of an automotive fender panels are numerically simulated by considering the die deformation found by the simultaneous structural analysis of press and dies. By coupling the forming analysis and the structural analysis, the die deformation is simultaneously taken into account in the forming process. Furthermore, for the consideration of load difference transferred among the upper die, punch, and blank holder due to the changes in sheet thickness, the gap elements are employed instead of the blank sheet in the structural analysis. The numerical simulation results of an automotive finder draw panel are compared with the measurements. The comparison of the forming and spring-back analysis results between the rigid die and the deformed die shows that the consideration of tool deformation can predict more accurately the forming and spring-back of sheet metals.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.21 no.1
• /
• pp.107-112
• /
• 2013

Base on insurance vehicle collision and bodily injury claim reports, 23,655 cases of vehicle to vehicle accidents occurred in Korea 2010 are investigated in order to understand vehicle damage severities, repair costs and occupant injury types. The results of our statistical analysis reveal that minor damages with small dent or scratches on vehicle body panels which is assumed to imply during very low speed crashes are major portion of accident severities types. The most vulnerable body regions due to the real-world accident are neck. The 86.3% of total injured driver in minor rear damaged vehicles has reported neck pains and they are followed by whole bodies and head but with much lower occurrence rates.