• Journal of the Microelectronics and Packaging Society
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• v.26 no.4
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• pp.1-6
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• 2019

Recently, as electric vehicles and hybrid vehicles are widely used, the use of rechargeable batteries is increasing. Electric and hybrid cars are made up of hundreds to thousands of electric cells depending on the car model. And the assembly process of the cells and modules requires a variety of bonding process. Meanwhile, in order to connect several cells in series, Cu used as a cathode and Al of an anode must be bonded. In this paper, the characteristics of Al and Cu metals, laser types, characteristics and principles of welding lasers for welding of Cu and Al electrodes are introduced.

• Journal of Applied Reliability
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• v.17 no.4
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• pp.273-279
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• 2017

Purpose: Recently, Issues on security for vehicles are getting increased all around the world. Especially, hood panel needs to be thinner for the protection of pedestrians. But thinner panel makes durability get worse. So, it is needed to satisfy both of them. Methods: Durability effectiveness will be studied because properties and assembly allowance of over-slam bumper mostly affects durability of hood panel. Overlap of over-slam bumper can be made in production line and it can affect durability of spot welding in hood inner panel. Daguchi method is used to catch the condition in which load gets smaller and location, hardness and quantity of overlap are selected to be factors. Durability effectiveness is analyzed with the factors. Result: the mechanism that affects on spot welding is identified. The test was conducted in both open/close and driving condition and the relation between both conditions is analyzed. Conclusion: The test contributed to durability of hood panel with optimization of over-slam bumper.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.1
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• pp.87-95
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• 2012

In recent years, laser-arc hybrid welding has begun to be adopted for assembly welding of automotive bodies and parts, because the hybrid welding process can weld lapped steel sheets having a larger gap than is possible with laser welding. In this paper, to predict the twist deformation by the hybrid welding when brackets are welded in B pillar of a passenger car, the residual stress using CAE is analyzed and the deformation result of CAE is compared with the measured deformation. First of all, after modeling heat source as intended to be expressed with laser-arc hybrid welding method, heat source fitting is done with welding conditions and a section of welding part obtained through specimen test. In case of heat source functions, laser used conical source and arc used double ellipsoid source. Through the local model analysis, elements which are located in the center of the model are selected. The elements are called WME(Welding Macro Element). This WME is extruded in the welding lines and welding phenomenon of complex parts is accomplished. The deformation amount after hybrid welding is got through a simulation, the validity of simulation is verified by measuring the panel and comparing with the simulation result.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.7
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• pp.3184-3190
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• 2013

These days, the great part of design processes in the field of ship or offshore manufacturing are planed and implemented using the customized CAD system for each ship-building companies. It means that all information for design and production could be extracted and reused at the useful other area cost considerable time and efforts. The representative example is the estimation of welding length and material amount which is demanded during the construction of ship or offshore structures. The proper estimation of welding material to be used and the usage of them at the stage of schedule planning is mostly important to achieve the seamless process of production and expect the costing in advance. This study is related to the calculation of welding length and needed material amount at the stage of design complete utilizing the CAD system. The calculated amount are classified according to welding position, stage, block, bevel and welding type. Moreover it is possible to predict the working time for welding operation and could be used efficiently for the cost management using the results of this research.

• 대한공업교육학회지
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• v.33 no.1
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• pp.282-296
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• 2008

Present automobile robot welding use $CO_2$ inert gas as a shielding fluid. The inert gas is spreading out and consumable. This present welding mechanism interfered with the welding nozzle. After welding several places have welding defects. Therefore, to reduce the $CO_2$ inert gas and to avoid interference with the material and to increase production modified nozzle which composed of cap and tip are needed. Suggested modified nozzle assembly composed of two stages i.e. $1^{st}$ and $2^{nd}$ stage. At the second stage it has 8 holes which is 3mm of diameter around the circumference. On the base of experimental results the inert $CO_2$ gas discharge reduced to 47% and welding defects decreased also. Modified two stage welding cap can be applied to the present robot welding machine and save the prime cost.

• Laser Solutions
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• v.18 no.1
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• pp.1-6
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• 2015

High welding speed and narrow weld seam are favorable for welding of magnesium alloy. Magnesium alloy is recommended for the smart frame because it has several advantages such as low density, high thermal conductivity, EMI shielding capability and good cast ability. This study is for the assembly welding of the magnesium smart frame with high productivity, good performance and low cost. The window for battery on AZ91D frame produced by die-casting was prepared by CNC machining. Corresponding AZ31 blank of 0.2mm thickness was prepared by die-blanking cut. All system set was fixed at the stationary bed but the laser beam was manipulated by scanner up-to 1,000mm/s speed. The weld joint between AZ31 sheet and AZ91D frame was welded by fiber laser on 850~1,000W output power. The joint showed penetration enough but some humping bead. The distortion by the weld heat was almost free because of the quick dissipation of the heat by small beam size and fast welding. Consequently, the thinner magnesium foil was assembled successfully to the magnesium frame of mobile phone.

• Journal of Welding and Joining
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• v.34 no.1
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• pp.21-25
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• 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.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.400-404
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• 1997

This paper presents spatial relationshaps and engineering features for the feature based modeling of Sheet Metal Weld Assemblies (SMWA) that are made of sheet metal components through are welding processes. Spatial relationships in ProMod-S, a sheet metal product modeler,are further extended for the SMWA modeling. Some spatial relationships for special weld joint types are newly introduced. The geometrical and topological relations between spatial reationship, mating features, and assembly features are defined. Finally, assembly data stucturess for the product modeling of SMWA are proposed. They are an engineering relation to represent the constraints between component features, and a mating bond to integrate component design information.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.2
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• pp.228-233
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• 2002

TWB(Tailor Welded Blanks) is one of the recent techniques to reduce the weight and cost of the body members. To apply the TWB technique, we must decide the position of the welding line and the thickness of the welded blanks. Although many researchers have tried to check the formability of welded blanks, there are not so many researches from the structural point of view. In this paper, the TWB technique is applied to combine the door inner panel and the hinge face panel into one piece. The finite element structural analysis of the door assembly leads to the final design of the tailor welded door inner panel, which shows the mass reduction of 1.08kg without the sacrifice of the structural stiffness. The structural stiffness analysis includes the frame stiffness analysis, the belt line stiffness analysis, the door sagging analysis and the vibration analysis.

• Proceedings of the KWS Conference
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• 2005.06a
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• pp.367-369
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• 2005

For the purpose of the optimization or the break through of production processes, it is essential to understand or theoretically interpret dominant mechanisms of the processes, and further more, archive them. and utilize them combining some of them which are needed. Especially in the technology for micro- or nano-scaled objects, adhesion phenomenon is no more negligible, because the adhesion force is proportional to the size of objects meanwhile gravity force is proportional to the third power of it. Author has been working about the mechanisms for micro-assembly processes, which include joining processes and manipulation processes. In the present paper, the strategy and the progress to establish the micro-assembly technology archive are introduced. Some of the mechanisms are introduced with related basic approaches to the adhesion phenomena. Also it will be expressed that our data base project for the surface and interfacial energies is strongly related to these basic approaches.