• Journal of the Korea Academia-Industrial cooperation Society
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• v.12 no.5
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• pp.2025-2030
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• 2011

Recently, several vehicle manufacturers have used the aluminum side door impact beam in order to reduce the vehicle weight and costs. But, the aluminum impact beam may cause the reduction of the side door strength and the side impact capability. Therefore, this paper optimized the section dimension and section shape of the side door impact beam to satisfy the legislation of the side door strength and maintain the side impact capability as well as steel impact beam

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.4
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• pp.379-385
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• 2016

Door impact beam plays a key role in minimizing the occupant injury within the side impacted vehicle through preventing intrusion of the impacting vehicle. Steel pipe type door impact beam has been widely adopted since it has simple structure and the overall strength is easily determined according to the pipe size. The brackets welded at pipe ends connect the door impact beam and the door panels by spot welds. In this study, first, the effect of pipe thickness, bracket thickness and door mounting stiffness was respectively analyzed. Next, application of the tailor rolled pipe was examined and several alterations of the bracket mounting method were considered. Application of tailor rolled pipes with superior bracket mounting method showed remarkable strength enhancement and weight reduction possibility in comparison with the current door impact beam.

• Transactions of the Korean Society of Automotive Engineers
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• v.25 no.1
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• pp.74-81
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• 2017

The door impact beam of the side-impacted vehicle plays a key role in securing occupant safety by preventing intrusion from the impacting vehicle. Despite the low production cost, the press door impact beam has been adopted sparingly because of the strength inferiority. In this study, the design technologies of the press beam aimed at improving bending strength were investigated. First, the effect of the section shape and size was examined. Next, thickness and material strength were increased. Also, the TRB beam application was simulated by varying combined thickness. Some TRB beams with reduced weight exhibited bending strength over the strength of the pipe beam. Then, the beam with a closed center section also showed remarkably enhanced maximum bending strength.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.7-12
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• 2008

A hot stamping technology of vehicle door impact beam made of thin sheet steel has been developed, with the aim of ensuring occupant safety in a side collision. This technology has been implemented to increase the strength of vehicle body parts and to reduce not only the weight of door impact beam but also the number of work processes. Mechanical tests were performed to obtain material properties of hot-stamped specimen and those were used as input data in stamping and structural simulation for optimal design of door impact beam. Strength of hot-stamped door impact beam increased to the value 102% higher than that of conventional pipe-shaped door impact beam and structural simulation showed that hot-stamped door impact beam achieved 28% weight reduction.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.6
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• pp.80-87
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• 2020

The currently observed trend in car manufacturing is to increase energy-efficiency by producing lighter cars. This study examines the replacement of particular parts, specifically around the impact beam, with material composites 30% lighter than conventional steel currently used. The shape of the impact beam was determined as the trapezoidal cross-sectional area with central reinforcement, using three-point bending analysis. A prototype was fabricated based on the findings of our study and its performance was evaluated by the three-point bending analysis; 2 ply of aramid applied for its displacement. The performance of the final prototype for the door assembly was evaluated using a side-door strength test, which resulted to measured initial strength of 10.5 KN and intermediate strength of 15.6 KN. This research provides a promising solution for better impact beam manufacturing.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.6
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• pp.797-803
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• 2010

A vehicle door impact beam made of a thin sheet of steel has been constructed using hot stamping technology with the aim of ensuring occupant safety in the event of a side collision. This technology has been used to increase the strength of the vehicle body parts and to reduce the weight of the door impact beam as well as the number of work processes. Mechanical tests were performed to determine the material properties of the hot-stamped specimen and the results of the tests were used as input data in stamping and structural simulation in order to obtain the optimal design of door impact beam. The strength of the hot-stamped door impact beam increased to a value that was 102% higher than that of conventional pipe-shaped door impact beam. A weight reduction of 34% was also achieved.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.82-87
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• 2012

The purpose of this study is to produce a side impact beam with high tensile steel using a roll forming process. The door side impact beam plays an important roll in a car because it protects passengers from external crash. The roll forming process is a continuous bending process wherein a long metal sheet is bended as it continuously passes several rolls. The characteristic of this study is that an impact beam is produced by a continuous process using a ultra high strength steel without a hardening heat treatment. A model was determined by analysing plasticity of a cross section shape considering high strength. Design parameters of the impact beam was determined by crash-analysing the model. Workpiece products were manufactured by designing dies for roll forming and setting them up in a following process line. Results of a bending test and a FEM analysis was considered and reviewed.

• Journal of Auto-vehicle Safety Association
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• v.13 no.3
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• pp.60-68
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• 2021

Invisible passenger airbag door system of hard panel types must be designed with a weakened area such that the side airbag will deploy through the instrument panel as like intended manner, with no flying debris at any required operating temperature. At the same time, there must be no cracking or sharp edges in the head impact test. If the advanced airbag with the big difference between high and low deployment pressure ranges are applied to hard panel types of invisible passenger airbag (IPAB) door system, it becomes more difficult to optimize the tearseam strength for satisfying deployment and head impact performance simultaneously. It was introduced the 'Operating Window' idea from quality engineering to design the hard panel types of IPAB door system applied to the advanced airbag for optimal deployment and head impact performance. Zigzab airbag folding and 'n' type PAB mounting bracket were selected.

• Journal of the KSME
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• v.35 no.8
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• pp.709-715
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• 1995

날로 그 중요성이 대두되고 있는 환경보존 문제에 능동적으로 대응하고 여러 계층 소비자의 안 전도, 쾌적성 등에 관련된 요구, 성능의 수준향상에 효과적으로 대처하기 위해서는 차량의 경량화 기술이 가장 먼저 선행되어야 할 과제이다. 경량화를 추구하는 방법은 최적설계 개념을 이용한 구조합리화에 의한 방법과 알루미늄, 강화 플라스틱 등 신소재 대체에 의한 방법이 병행 연구 되고 있다. 이 글에서는 구조합리화를 통한 경량화 목표를 달성하기 위해 설계 초기 단계에 활용 가능한 단순 보 모델 개발의 필요성에 관해 언급하고 실차의 도어 측면 붕괴강도(door side intrusion strength), 루프 붕괴강도 (roof crush strength) 해석을 위한 단순 보 모델 개발에 관해 소개하고자 한다.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.5
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• pp.103-110
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• 2021

The mounting performance of the GFRP(Glass fiber Reinforced Plastic) beam and the mechanical mounting of the steel bracket was studied to be mounted as a GFRP impact beam on the side door of the passenger car. Moreover, an open-hole tensile test was performed to evaluate breakage tendency based on GFRP stacking conditions. Furthermore, the tightening strength of rivets and bolts was compared using the single lap-shear tension test for the GFRP stacking pattern. Additionally, the GFRP beam and bracket mounting features were designed; moreover, the prototype and bracket were assembled. Additionally, the bracket mounting bending test and the door assembly static bending test were performed to verify the stability of the bracket mounting. In the bracket fastening bending test, no breakage occurred in the connection part between the GFRP beam and the bracket, and it showed 67% (24.4 kN) improved performance compared to steel. In the static bending test of the door assembly, the initial average reaction force increased by 25% compared to the steel, and the performance of all FMVSS-214 regulations was satisfied. The replacement of GFRP impact beams resulted in a 30% weight reduction