• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.6
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• pp.78-84
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• 2017

Consistent efforts have been made to reduce the weight of automotive parts by using lightweight materials. This has resulted in the replacement of conventional steels in car body structures with high-strength steels, and the current usage rate has reached 50%. This study examines the structural stiffness and energy absorption capability of bumper beams made of high-strength steels. New types of bumper beam cross sections are proposed.The structural stiffness and maximum bending force were computed via finite element analysis as about 25tons and 7.5tons/mm, and there were no significant differences among the proposedcross sections. Dynamic analysis was also carried out to investigate the energy absorption capabilities of the bumper beams, and the effects of materials and thickness reduction were analyzed. High-strength steel can be used to achieve weight reduction with comparable structural performance to conventional bumper beams.

• Composites Research
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• v.31 no.1
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• pp.37-41
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• 2018

The aim of the current work is to characterise a piecewisely-integrated composite bumper beam based on the IIHS bumper crash protocol. IIHS bumper crash FE analysis for an aluminium type bumper beam was carried out to get the information about the dominant loading types at several regions in the bumper beam during crash. In the meantime, robust stacking sequences against tension and compression have been searched for using FE analysis of a coupon type model. After determining most effective stacking sequences for tension and compression, three-point bending simulation was preliminarily carried out to investigate the combination performance of them. Finally, IIHS bumper crash FE analysis for the piecewisely-integrated composite bumper beam, which consisted of the combination of tension effective stacking sequence and compression efficacious stacking sequence, was conducted and the result was compared with other types of composite bumper beams. It was found that the newly suggested piecewisely-integrated composite bumper beam showed superior crashworthy behaviour to those of uni-modal stacking sequence composite bumper beams.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.163-170
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• 2003

The back beam for a automotive bumper was roll formed to improve performance, reduce weight and save cost. For the back beams produced by conventional stamping and roll forming, the crashworthiness analyses were carried out by numerical simulation and real impact test. The characteristic properties and applicability of the roll formed back beam are discussed from the results of the analyses.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.8
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• pp.797-801
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• 2013

Today's automotive industry is evolving toward low-emissions or zero-emissions high-efficiency vehicles. Highly efficient power sources are required, as well as high strength steels for various parts to increase safety. In this study, we investigated the roll-forming process for the development of high strength, lightweight steel bumper beams. The roll-forming process was analyzed using the software package Shape-RF in combination with a rigid-plastic finite element method model. An optimal roll-forming process based on roll-pass was obtained using finite element method simulations.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.26 no.4
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• pp.410-417
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• 2017

Hydro-forming is being employed increasingly to realize lightweight vehicular parts. The bumper beam produced by this process weighs 30% less than the conventional products with equal stiffness. However, hydro-forming involves complex parameters to obtain the target geometry and low residual stress. Parametric studies are conducted using finite element analysis to obtain optimized process conditions. Through these numerical approaches, the internal and holding pressures and feeder forward stroke along the extruded direction are optimized to achieve low residual stress and to minimize springback. The numerical results are verified by experimental observations made by employing a three-dimensional laser scanner. The numerical and experimental results are compared in terms of the springback. Both results show similar tendencies.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.337-340
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• 2006

Aluminum extruded profiles have been mostly used only a few automotive parts until now, such as roof rail, sunroof frame and bumper beams. However, Aluminum Extru-form technology, which was recently developed by foreign advanced manufacturer, made it possible to apply the aluminum extruded profiles to suspension parts of passenger and RV cars. It could be obtained by optimized billet casting, extrusion and stretch bending technology. It was possible to have the excellent weight reduction and the competitive price comparing with conventional process of aluminum for automotive parts. Combining additional process technology such as machining and joining, the application can be extended to various automotive parts. We have developed high strength aluminum alloy and fabricated subframe and suspension arm by extruforming process.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.5
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• pp.806-811
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• 2013

In this study, to prevent the nonhomogeneity of fiber orientation during the molding of GFRP composites, GFRP prepreg was fabricated using roving fiber and polypropylene resin. Analyses on the degree of impregnation, tensile strength, and microstructure were conducted on the fabricated prepregs. A lower pulling speed, higher resin temperature, and longer die length showed a greater degree of impregnation of the prepreg. The scanning electron microscope (SEM) micrograph showed, a homogeneous fiber orientation. As a result, fundamental techniques for improved productivity were suggested for the manufacturing field.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.7 s.166
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• pp.1075-1084
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• 1999

The family of unidirectional continuous fiber reinforced polymeric composites are currently used in automotive bumper beams and load floors. The material properties and mechanical characteristics of the compression molded parts are determined by the curing behavior, fiber orientation and formation of knit lines, which are in turn determined by the mold filling parameters. In this paper, a new model is presented which can be used to predict the 3-dimensional flow under consideration of the slip of mold-composites and anisotropic viscosity of composites during compression molding of unidirectional fiber reinforced thermoplastics for isothermal state. The composites is treated as an incompressible Newtonian fluid. The effects of longitudinal/transverse viscosity ratio A and slip parameter $\alpha$ on the buldging phenomenon and mold filling patterns are also discussed.

• Journal of Welding and Joining
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• v.33 no.6
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• pp.27-35
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• 2015

Laser welding sector in the automotive industry has been widely recognized as one of the most important bonding processes, such as parts welding. Efforts to improve productivity and weld quality have been progressing steadily. In addition, laser welding is suitable for welding process that can produce high-quality welds suitable for flexible production and small quantity batch productions. In order to ensure the rigidity of the material, high strength material are applied to more than 1 GPa class body parts and automotive bumper beams. However, not only the situation is that the trend of domestic research, but also development is based on product molding considering freedom of shape where reinforcement is applied to meet the safety regulations and high-speed crash performance, despite the use of high strength materials. The tendency for heat-affected zone (HAZ) softening phenomenon common in areas of laser welded high tensile steel welding confirmed the occurrence of weld softening effect according to the process parameters. Based on this, range of process parameters could be selected for ensuring weld quality.