• Transactions of the Korean Society of Automotive Engineers
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• v.21 no.2
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• pp.45-54
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• 2013

In this paper, a theoretical weight-reduction method was suggested to substitute an underframe material of a box-type bodyshell having cut-outs with an alternative light-weight material. To utilize the material substitution method previously developed for a box-type hybrid bodyshell not having cut-outs, we derived a box-type baseline model without cut-outs which is similar to the stiffness condition of a box-type bodyshell having cut-outs. To do this, the thicknesses of roof and walls of the baseline model were determined such that the deflection of the baseline model under a distributed vertical load condition is equal to the sum of the theoretical section deflections of the original box model with cut-outs. Next, to derive a hybrid bodyshell by under-frame material substitution, the material substitution method for a box-type hybrid bodyshell without cut-outs was applied to the box-type baseline model. Finally, we compared the FE simulation results of the derived hybrid bodyshells having cut-outs for various materials with the theoretical results of the suggested method, and we obtained their good correlations.

• Composites Research
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• v.21 no.4
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• pp.1-6
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• 2008

This paper explains fire safety tests of a hybrid composite train carbody with carbon/epoxy sandwich bodyshell and stainless steel underframe. In this study, a large scale mock-up was used to evaluate the fire safety of the composite train carbody. The test was conducted to the bare composite carbody mock-up without interior facilities and the fully equipped one. Tile fire propagation and temperature distribution of the carbon/epoxy bodyshell and the glass phenol interior panels was evaluated under the real fire accident scenario. The test scenario was based on the DaeGu subway fire accident. From the tests, both the surface temperature of the interiors and the composite bodyshell wore lower than tile ignition temperature. In addition, the fire spread along the surface of the interiors and bodyshell was not occurred.

• Journal of the Korean Society for Railway
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• v.15 no.2
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• pp.97-103
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• 2012

Composite honeycomb sandwich plate is light and strong. It is easy to produce. It began to be applied to the bodyshell of rolling stock. Generally, weight saving amounts to 27%. However, the material cost of it is much higher than that of aluminum extrusion profile, which prevents popular use of it for bodyshell. In this paper, manufacturing processes of two light materials were compared to investigate cost impact. After cost breakdown was defined, economics of two materials was analyzed using the previous cost data. Easy production of composite bodyshell could compensate for higher material cost. Mass production of composite bodyshell can make the equipment cost lower for the composite bodyshell so that it may have strong competitiveness to the aluminum bodyshell. Operational energy saving due to weight reduction was also presented referring to the actual statistical data in a metro line.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.6
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• pp.50-61
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• 2007

The structural stiffness, strength and stability on the bodyshell and floor structures of the Korean Low Floor Bus composed of laminate, sandwich panels and metal reinforced frame were evaluated. The laminate composite panel and facesheet of sandwich panel were made of WR580/NF4000 glass fabric/epoxy laminate, while aluminum honeycomb or balsa was applied to the core materials of the sandwich panel. A finite element analysis was used to verify the basic design requirements of the bodyshell and the floor structure. The use of aluminum reinforced frame and honeycomb core was beneficial for weight saving and structural performance. The symmetry of the outer and inner facesheet thickness of sandwich panels did not affect the structural integrity. The structural strength of the panels was evaluated using Von-Mises criterion for metal structures and total laminate approach criterion for composite structures. All stress component of the bodyshell and floor structures were safely located below the failure stresses. The total laminate approach is recommended to predict the failure of hybrid sandwich composite structures at the stage of the basic design.

• Composites Research
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• v.18 no.3
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• pp.7-13
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• 2005

This paper presents a study on the low velocity impact response of the woven fabric laminates for the hybrid composite bodyshell of a tilting railway vehicle. In this study, the low velocity impact tests for the three laminates with size of $100mm\times100mm$ were conducted at three impact energy levels of 2.4J, 2.7J and 4.2J. Based on the tests, the impact force, the absorbed energy and the damaged area were investigated according to the different energy levels and the stacking sequences. The damage area was evaluated by the visual inspection and the C-scan device. The test results show that the absorbed energy of [fill]8 laminate is highest whereas (fill2/warp2)s is lowest. The [fill]8 laminate has the largest damage area because of the highest impact energy absorption.

• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.5
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• pp.100-112
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• 2011

This paper studied on a theoretical approach to predict structural performances and weight -reduction rates of hybrid bodyshells in case that the material of underframe structure is substituted. To choose other light-weight materials to be substituted for the original underframe material, compressive, bending and twisting deformations are considered under constant stiffness and strength conditions, which derive some new weight-reduction indices from a structural performance point of view. Next, these weight-reduction indices were verified using the finite element analyses of some simplified examples. It is shown that the derived indices to estimate the weight-reduction can be utilized as a good criterion for material substitution of the underframe at a basic design stage.

• Proceedings of the KSME Conference
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• 2005.11a
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• pp.121.1-121.1
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• 2005

• Journal of the Korean Society for Railway
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• v.9 no.6 s.37
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• pp.635-643
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• 2006

In this paper, a theorectical approach is studied to predict structural performances and weight-reduction rates of hybrid bodyshells in case that the materials of roof structures are substituted. To determine other light-weight materials to be substituted for the original roof materials, bending and twisting deformations are considered under constant stiffness and strength conditions, which derive some new weight-reduction indices from a structural performance point of view. The indices derived to estimate the weight-reduction can be utilized as a good criterion at the conceptual design for material substitution of the roofs.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2005.11a
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• pp.264-267
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• 2005

Impact damages are very important in the perspective of residual strength of composite structures such as aircrafts, ships, and trains because those damages are sometimes not visible on the surface of the point of impact and the impact resistance of laminated composites is usually not so high. Thus, the impact characteristics of laminated composites should he investigated for the safety of composite structures. This paper investigates the low-velocity impact and damage detection conducted on woven carbon/epoxy laminates. Experimental results show that the type of damage is dependent on the impact energy level and the delamination area becomes larger as the impact energy increases.

• Proceedings of the KSR Conference
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• 2005.05a
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• pp.251-256
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• 2005

This study was performed the heat transportation ratio of three types of the following sandwich panel by KS F 2278(2003) ; Type ${\sharp}1$ : Carbon/epoxy Aluminum Honeycomb and Balsa Core Sandwich Panel(Thickness : 37mm), Type ${\sharp}2$ : Carbon/epoxy Aluminum Honeycomb Core Sandwich Panel(Thickness : 57mm), and Type ${\sharp}3$ : Carbon/epoxy Aluminum Honeycomb Core Sandwich Panel(Thickness : 37mm). Also was performed the heat transportation of next three types of the following sandwich panel by KS F2277(2002) ; Type ${\sharp}4$ and ${\sharp}5$ : 27mm, and 35mm thick-Aluminum Honeycomb Sandwich Panels, and Type ${\sharp}6$ : 27mm thick-Foaming Aluminum Sandwich Panel. It is the larger area between the skin and core, the heat transportation ratio is the higher, and when it is composed of the hybrid composite structure, good insulation property was shown.