• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.199-202
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• 2009

In roll forming process, a sheet metal is continuously progressively formed into a product with required cross-section and longitudinal shape, such as a circular tube with required diameter, wall-thickness and straightness, by passing through a series of forming rolls in arranged in tandem. Tn this process, each pair of forming rolls installed in a forming machine play a particular role in making up the required cross-section and longitudinal shape of the product. In recent years, that process is often applied to the bumper rail in the automotive industries. In this study, a optimal Front Bumper Beam manufacturing technology, model deign and proper roll-pass sequences can be suggested by forming number of roll-pass and bending angle. And also effects of the process parameters on the final shape formed by roll forming defects were evaluated.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2003.10a
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• pp.137-140
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• 2003

Impact of Automotive GMT(Glassfiber reinforced Mat Thermoplastic) Bumper for '5Mhp Barrier Test'was simulated using ls-dyna. The FE model consists of foam which is energy absorber, bumper beam and stay etc. Bumper intrusion and deflection was compared with the experimental results. Effects of uncertainty of material property and deviation of impact velocity were considered and results were compared with those of base design. Effects of number of integration points through th thickness was also investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.991-992
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• 2012

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.4
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• pp.206-215
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• 2002

It is to be classified into friendly environment and safety problems, as a main technology development of the recent automotive industry. As these tendency, lots of automobile companies focus on a reduction of fuel expenses and strengthen of crash safety using high strength steel. In this study advanced technologies such as tailored blanks, aluminum extrusion and high strength steel forming applied to bumper beam will be described. As a result of impact analysis and an actual impact test, in terms of beam performance and a possibility fur the mass production will be discussed.

• International Journal of Automotive Technology
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• v.7 no.2
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• pp.209-216
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• 2006

A study has been conducted for an optimal processing and an apparatus for manufacturing a laser welded tube for one-body formed bumper beam. The tube dimensions used in calculation were the thickness of 1.4 mm, the diameter of 105.4 mm and the length of 2000 mm. The tube was formed of a cold rolled high strength steel plate(tensile strength of 600 MPa). The two-roll bending method was the optimal tube forming process in comparison with the UO-bending method, the bending method on the press brake, the multi-step continuous roll-forming method and the 3-roll bending method. Monitoring of the welding quality was conducted and the seam tracking along the butt-joint lengthwise to the tube axis was also examined. The longitudinal butt-joint was welded by using a $CO_2$ laser welding machine equipped with a seam tracker and a plasma sensor. The $CO_2$ laser tube welding machine could be used for precise seam tracking and real-time monitoring of the welding quality. As a result, the developed laser welded tube could be used for a one-body formed automobile bumper beam.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.7
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• pp.136-144
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• 2004

Optimal process and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from a cold rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.683-684
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• 2009

• Journal of the korean Society of Automotive Engineers
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• v.13 no.3
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• pp.13-18
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• 1991

여기서는 자동차 분야중 Plastic이 가장 많이 적용되고 있는 Bumper의 초기 설계 가능성 확인(Feasibility study) 및 최적 설계를 위한 유동해석, 구조해석 그리고 Blow Molding Back-Beam 해석을 위한 PITA(Polymer Inflation and Thinning Analysis) 등의 기법들에 대한 내용 및 적용 방법 등에 대하여 서술하였다. 특히, Energy Absorbing 역할을 하는 Back-Beam은 Blow Molding에 의한 설계방법에 촛점을 맞추었다.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.11a
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• pp.829-830
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• 2010

• Journal of the Korea Academia-Industrial cooperation Society
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• v.12 no.4
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• pp.1552-1558
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• 2011

In this paper, the automotive beam using aluminium foam is designed and the impact analysis is carried out. The analysis model is the beam of actual size with B- type section structure. At the frontal crash of low speed, ANSYS AUTODYN is used by predicting the behavior of deformation and its internal energy. By the use of 7075-T6 aluminum alloy, the weight is reduced as much as 55% than steel. The deformation at the bumper foam of aluminum is similar with that of steel and the impact energy reduction at aluminum is more than steel. The foam filled with aluminum as much as 50 % has more impact energy absorption than the completely filled aluminum foam.