• 전력전자학회:학술대회논문집
• /
• 전력전자학회 2000년도 전력전자학술대회 논문집
• /
• pp.581-586
• /
• 2000

Gas metal arc welding(GMAW) uses a continuously fed electrode as a filler metal. The arc is shielded from atmospheric contamination by an inert gas active or inert/active gas mixture delivered through the welding gun and cable assembly. The recent research topics on $CO_2$ are welding machines are focused mainly on the reduction method of generated spatter by using new type consumable electrode metal or inverter control method. The various current waveform control methods have been researched for welding performance improvement. Until now current waveform control methods reduce to spatter occurred by instantaneous short circuiting,. but these methods is drawback that no reduce spatter occurred by arc reignition. In this paper the previous arc reignition current control method for welding performance improvement of inverter arc welding machine is studied and compared the various current control methods with the previous arc reignition current control method.

• 한국정밀공학회지
• /
• 제22권5호
• /
• pp.113-120
• /
• 2005

Because of the turbulent markets and the increasing demand on product quality, the application of new technology to practice is increasingly important. In case of automotive industries, they take interest in laser welding to solve these problems because laser welding has many advantages such as good accessibility, welding quality, fast welding speed and so on. To apply this technology to welding of car body, the data of laser welding are collected through lots of the experiment according to the material, geometry and layer number of welding points. Based on the experiment results and the information of product, i.e. the car side panel, the clustering of stitches for laser welding was carried out and the optimal equipments are selected through the comparison between the requirements of welding and the potential of equipments. Using these results, laser welding cell for the car side panel are configured with the concept of the digital manufacturing, which ensures maximum planning security with visualization and simulation. Finally, the optimal laser welding cell is chosen by the evaluation of alternative cells with assessment criteria.

• Journal of Welding and Joining
• /
• 제34권3호
• /
• pp.6-11
• /
• 2016

Joining Al/Fe dissimilar metals is becoming a subject of special interest in the assembly of automotive parts as a trade-off between the weight lightening and the cost reduction. Although various studies have been introduced to join Al alloy with the steel sheet by fusion welding, weak joint strength and galvanic corrosion still remained as problems to be solved. As a solid state welding, friction stir welding has been preferred to fusion welding processes in the dissimilar metal joints. This study investigated friction stir spot welding (FSSW) of Al alloy to the thin steel sheet with a thickness of 0.65 mm. The conventional FSSW is a stationary spot welding process but new approach adopted an additional circumferential movement in company with high speed tool rotation. A full factorial experimental design was implemented, and the main and interaction effects of parameters were analysed on the failure load in the tensile shear test. The direction and radius of rotation were statistically significant parameters and these two parameters affected the joint width and the shape of the hook.

• Journal of Welding and Joining
• /
• 제34권1호
• /
• pp.21-25
• /
• 2016

The automotive vehicle is made through the following processes such as press shop, welding shop, paint shop, and general assembly. Among them, the most important process to determine the quality of the car body is the welding process. Generally, more than 400 pressed panels are welded to make BIW (Body In White) by using the RSW (Resistance Spot Welding) and GMAW (Gas Metal Arc Welding). Recently, as the needs of light-weight material due to the $CO_2$ emission issue and fuel efficiency, new joining technologies for aluminum, CFRP (Carbon Fiber Reinforced Plastic) and etc. are needed. Aluminum parts are assembled by the spot welding, clinching, and SPR (Self Piercing Rivet) and friction stir welding process. Structural adhesive boning is another main joining method for light-weight materials. For example, one piece aluminum shock absorber housing part is made by die casting process and is assembled with conventional steel part by SPR and adhesive bond. Another way to reduce the amount of the car body weight is to use AHSS (Advanced High Strength Steel) panel including hot stamping boron alloyed steel. As the new materials are introduced to car body joining, productivity and quality have become more critical. Productivity improvement technology and adaptive welding control are essential technology for the future manufacturing environment.

• 대한용접접합학회:학술대회논문집
• /
• 대한용접접합학회 2002년도 Proceedings of the International Welding/Joining Conference-Korea
• /
• pp.181-186
• /
• 2002

Laser welding application for car body manufacturing has many advantages in the stiffness and the lightness of vehicle, the productivity of assembly line, and the degree of freedom in design. This presentation will express the innovation of car body manufacturing including parameter optimization, process modeling, and system integration. In this application the investment for systems was cut down dramatically by real time switching over the laser path between two welding stations. Points of technical discussion are as follows: optimization of parameters such as laser power, robot speed and trajectory, compact and useful design of jig & fixture to assure welding quality for 3 sheet-layer zinc-coated steel, system integration between 4kW Nd:YAG laser device and the other systems, on-line real time welding quality monitoring system, perfect safety standards for high power laser, minimization of consumption costs such as arc lamp, protective glass for optic, etc. Laser welding has found a place on Hyundai's production plant in conjunction with the startup of mass production of new sports car, and this production system is the result of a collaboration of its engineers. Outer side sheets are joined to inner side sheets by 122 stitch welds totally. And the length is about 2.4meter.

• 한국안전학회지
• /
• 제22권6호
• /
• pp.20-26
• /
• 2007

The new integrated CAD-CAM systems induce an increasing demand for simulation tools, which are able to simulate industrial part assembly processes by welding, gluing, riveting or bolting(more generally by fastening). Concerning fastened flexible parts, there exist no efficient computational aid on tolerance and methodology available on the field. The first part briefly presents the approach method based on the finite element method for TADA(Tolerance Analysis of Deformable Assemblies). The second part compares the results obtained by simulation using the commercial FEM code with the measurements. The principal elements of dispersion have been identified and studied on an experimental basis in order to test the robustness of the TADA model. This has enabled us to verify the model's possibilities as regards industrial constraints such as the use of incompatible meshes or the use of triangular elements and so on.

• 한국레이저가공학회지
• /
• 제14권4호
• /
• pp.1-8
• /
• 2011

This study is about laser welded joints in order to replace the traditional screw connection of a differential gear and its case in the differential gear assembly. Screws are usually used to join these parts. But the screws take up weight and space. So we needed to improve the joining method. In the welding of a differential gear and its case, the quality is much harder to control, because the high carbon contents of the two components results in cold cracks. But a new method that adds wire allows these materials to be joined. Additionally, more distortions generally occurs in the welded joints than in screws. We tried to prove that laser welding is an available method for joining these parts through the measurement and various tests.

• 대한설비공학회:학술대회논문집
• /
• 대한설비공학회 2008년도 동계학술발표대회 논문집
• /
• pp.375-380
• /
• 2008

This study have processed the developing of vane damper with accurate control by using gear which is a flow-control equipment of marine boiler's FD fan on this research. For the developing of vane damper, we have corrected some problem from welding & assembly process by changing the design, and for the case of an emergency case, we have applied the easy disassembly & assembly on that vane damper. Compared to Rink type vane damper in current, we have focused on high efficiency with low price of that new developing damper. For selection of actuator, we have tried to find the propriety with our developing focus. Also, we have developed a jig of assembly processing for high productivity with quality, it caused the best assembly performance with heat-treated & processed parts.

• International Journal of Korean Welding Society
• /
• 제2권2호
• /
• pp.19-25
• /
• 2002

In recent years, techniques for micro-assembly with high repeatability under a scanning electron microscope (SEM) are required to construct highly functional micro-devices. Adhesion phenomenon is more significant for smaller objects, because adhesional force is proportional to size of the objects while gravitational force is proportional to the third power of it. It is also known that adhesional force between micro-objects exposed to Electron Beam irradiation of SEM increases with the elapsed time. Therefore, mechanical manipulation techniques using a needle-shaped tool by adhesional force are often adopted in basic researches where micro-objects are studied. These techniques, however, have not yet achieved the desired repeatability because many of these could not have been supported theoretically. Some techniques even need the process of trial-and-error. Thus, in this paper, mechanical and adhesional micro-manipulation are analyzed theoretically by introducing new physical factors, such as adhesional force and rolling-resistance, into the kinematic system consisting of a sphere, a needle-shaped tool, and a substrate. Through this analysis, they are revealed that how the micro-sphere behavior depends on the given conditions, and that it is possible to cause the fracture of the desired contact Interfaces selectively by controlling the force direction in which the tool-tip loads to the sphere. Based on the acquired knowledge, a mode diagram, which indicates the micro-sphere behavior for the given conditions, is designed. By referring to this mode diagram, the practical technique of the pick and place manipulation of a micro-sphere under an SEM by the selective interface fracture is proposed.

• 대한용접접합학회:학술대회논문집
• /
• 대한용접접합학회 2009년 추계학술발표대회
• /
• pp.29-29
• /
• 2009

On this research, laser welding technology for manufacturing automobile body is studied. Laser welding technology is one of the important technologies used in the manufacturing of lighter, safer automotive bodies at a high level of productivity; the leading automotive manufacturers have replaced spot welding with laser welding in the process of car body assembly. Korean auto manufacturers are developing and applying the laser welding technology using a high output power Nd:YAG laser and a 6-axes industrial robot. On the other hand, the robot-based remote laser welding system was equipped with a long focal laser scanner system in robotic end effect. Laser system, robot system, and scanner system are used for realizing the high speed laser welding system. The remote laser welding system and industrial robotic system are used to consist of robot-based remote laser welding system. The robot-based remote laser welding system is flexible and able to improve laser welding speed compared with traditional welding as spot welding and laser welding. The robot-based remote laser systems used in this study were Trumpf's 4kW Nd:YAG laser (HL4006D) and IPG's 1.6kW Fiber laser (YLR-1600), while the robot systems were of ABB's IRB6400R (payload:120kg) and Hyundai Heavy Industry's HX130-02 (payload:130kg). In addition, a study of quality evaluation and monitoring technology for the remote laser welding was conducted. The welding joints of steel plate and steel plate coated with zinc were butt and lapped joints. The quality testing of the laser welding was conducted by observing the shape of the beads on the plate and the cross-section of the welded parts, analyzing the results of mechanical tension test, and monitoring the plasma intensity and temperature by using UV and IR detectors. Over the past years, Trumf's 4kW Nd:YAG laser and ABB's IRB6400R robot system was used. Nowadays, the new laser source, robot and laser scanner system are used to increase the processing speed and to improve the efficiency of processes. This paper proposes the robot-based remote laser welding system as a means of resolving the limited welding speed and accuracy of conventional laser welding systems.