• Transactions of Materials Processing
• /
• v.23 no.2
• /
• pp.75-81
• /
• 2014

Progressive dies are used for metal stamping during which multiple operations are performed in a sequence. Material is fed automatically from a coil into the press and advances from one die station to the next with each press stroke. Transfer dies are used in high-volume manufacturing for round, deep-drawn, and medium-to-large parts. Several different operations may be incorporated within a transfer die such as blanking, bending, piercing, trimming, and deep drawing. The main challenge in the current study is how to deform a seat cushion panel meeting the design specifications without any defects. A complex automation die manufacturing technology for the automotive seat cushion panel, mixing both semi-progressive die and transfer die for continuous production, was developed.

• Transactions of Materials Processing
• /
• v.24 no.6
• /
• pp.400-404
• /
• 2015

For mass production of stamped parts, which require complicated in-press operations, it is always advisable to use a progressive die set. It is difficult to choose a progressive die set if the stamped parts need to be deep drawn and especially if they are unsymmetrical. Because unsymmetrical deep drawing parts are very sensitive to the effect of weight during moving to the next step, they are hard to exactly locate on the die face. An automotive seat side cushion panel is about 80mm high, unsymmetrical and its low edge needs hemming, so it is hard to produce even using a progressive die set. In the current paper a progressive stamping for seat side cushion panel was examined. Five strip bridges were considered to be strong enough to move to the next die as predicted by the CAE analysis.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.14 no.4
• /
• pp.126-133
• /
• 2015

To enhance the productivity and quality of the compound process of progressive dies and transfer dies, the semi-progressive method is applied in the material supply step to produce blanks, and then the transfer method is applied. Parts are transferred among processes by means of the finger and transfer bar in the transfer die, and the final seat cushion panel is produced. The main challenge in the current study is how to deform a seat cushion panel while meeting the design specifications without any defects. In order to obtain this technology, a sheet metal-forming simulation and die forming of the seat cushion panel were adopted; as a result, a compound die-forming technology for the automotive seat cushion panel, combining both semi-progressive die and transfer die for continuous production, was successfully developed.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.17 no.8
• /
• pp.200-207
• /
• 2016

The automotive seat is an important component that moves in sync with the driver and is actively being developed with various new functions. The aim of this work is to develop a lightweight seat cushion extension module using a lightweight material. To this end, a structural strength analysis, vertical strength test, and durability test were conducted. In the structural analysis, the maximum value of deformation under vertical load was 4.98 mm at the front of the upper panel. The maximum stress was approximately 105 MPa, which occurred at the point of contact between the upper and lower panels of the module. The vertical strength test showed a maximum vertical deformation of 5.31 mm under a vertical load, which differed from the analysis results by approximately 6.45%. The structural safety of the product was verified by the fact that it showed no harmful deformation or damage during operation after the vertical strength test and a durability test for 20,000 cycles. Furthermore, the use of engineering plastics made it possible to reduce the weight by approximately 30% compared to existing products. The lack of damage after tests verified the passenger safety, strength, and rigidity of the product. The results are expected to be applied for improving environmental and fuel efficiency regulations and preventing accidents due to driver fatigue. The applications of this module could be expanded various types of vehicles, as well as other industries in which eco-friendly and lightweight materials are used.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.24 no.5
• /
• pp.605-611
• /
• 2016

Mg alloy sheet exhibits significant differences in tensile and compressive yield stress depending on the temperature, as well as variations in its hardening behavior. Such unusual behavior makes it difficult to simulate the forming process of Mg alloy sheets. Results of analysis tend to deviate significantly from the experimental data because commercial software do not completely implement the unusual hardening behavior, yield asymmetry and temperature dependent changes in the Mg alloy's material properties. In the previous study, an in-plane tension-compression cyclic tester was developed to predict the cyclic behavior of Mg alloy sheets at an elevated temperature of up to $250^{\circ}C$. A new constitutive equation was suggested to analyze the unusual behavior, and was implemented in the commercial software in the form of user subroutine. In this paper, a stamping process of Mg seat cushion panel for automotive parts was simulated using the experimental data and user subroutine. Based on the analysis, an optimal temperature condition was determined and a stamping die shape at each step was suggested in the non-isothermal stamping of Mg alloy sheets.

• Proceedings of the KAIS Fall Conference
• /
• 2008.11a
• /
• pp.456-458
• /
• 2008

RV 차량의 쿠션 패널을 생산하여 조립하는 공정은 작업자의 오류로 인한 불량이 많이 발생된다. 본 연구에서는 이러한 불량을 제거하기 위한 화상검사장치를 개발함을 목적으로 한다. 이러한 장치개발은 쿠션패널 고정용 지그, 카메라 인식영역, 이송을 위한 X-Y테이블, 카메라 모듈, 제어기 로 구성되어진다. 본 논문에서 제안한 화상검사장치를 설계하고 화상인식 프로그램을 통해 불량을 판정하여 화상검사 시스템의 타당성을 검증하였다.