• Proceedings of the KSR Conference
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• 2002.10a
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• pp.54-59
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• 2002

In general, the aluminum extrusions are used to the light construction of the high speed rail vehicle structures. However, the research works ok the crashworthy design of the high speed rail vehicle structures are not published sufficiently because the crash test of high speed rail vehicle structures costs high and is complicated. So, a method that can predict crash characteristics of a large size structure like a high speed tail vehicle should be suggested. In this study, the scale model studies are performed to predict the impact energy absorption characteristics of full scale model. In the first place, we verified the theory of scale law using FE-simulation from the crashworthiness point of view. Secondly, we performed the crush test using scale model, made of aluminum sub structure. As a result, we could predict the crash characteristics using scale model by 10∼20% error.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.6
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• pp.471-478
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• 2016

This paper describes a method to design a lightweight modular bridge for a railway infrastructure system. A lightweight design was achieved using the material selection method. Aluminum extrusions and honeycomb sandwich composites were selected as the best materials to reduce the weight of the upper structure of a conventional modular bridge made of carbon-steel material. The structural integrity of the lightweight modular bridge was evaluated under vertical and wind loads. The twisting and bending natural frequencies were also evaluated to investigate its dynamic characteristics. The results showed that the structural integrity and natural frequencies of the lightweight modular bridge, made of aluminum extrusion and sandwich composites, satisfied the design requirements. Moreover, it was found that the weight of the conventional modular bridge made of carbon steel could be reduced by a maximum of 47% using lightweight materials.

• Journal of the Korean Society for Heat Treatment
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• v.35 no.6
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• pp.319-326
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• 2022

Direct extrusions of an aluminum 7075 alloy were carried out using 1500 ton machine with and without die cooling system. Cooling of extrusion die has been performed by the flow of liquid nitrogen and controlled by laser thermometer. Billet was 180 mm in diameter and 500 mm in length. The preheating temperatures of billet, container and die were 390℃, 400℃ and 450℃, respectively. Ram speed was kept with 1.25 mm/sec first. The change of ram speed was carried out during extrusion according to the observation of surface defects such as crack or tearing. Extrudates of 8.3 m in length, 100 mm in width and 15 mm in thickness were obtained to observe and analyze surface defects by optical microscopy and EBSD (Electron BackScattered Diffraction). In case of extrusion without die cooling cracks on the surface and tearing in the corner of extrudate occurred in the middle stage and developed in size and frequency during the late stage of extrusion. At the extrusion with die cooling the occurrence of defects could be suppressed on the most part of extrudate. EBSD micrographs showed that cracks and tearings have been resulted from the same origin. Surface defects were generated at the boundaries of grains formed by secondary recrystallization due to surface overheating during extrusion.

• Journal of the Korean Society for Railway
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• v.5 no.4
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• pp.231-236
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• 2002

Todays, crash safety requirements of the railway vehicle structures become important design criterion according to the increased driving speed and the lightweight construction. Although the crash analysis using computer simulation can be effectively applied to predict the crash performance of the railway vehicles in the early design stage, the optimized design w.r.t the crash safety could be realized by the crash tests with actual prototype vehicles. However, it is very expensive and time-consuming task to perform the crash test of the railway vehicles. As a measure to cope with the problem, in this paper, the scale modeling technique is suggested and experimentally verified to predict the impact energy absorption characteristics of full scale model of aluminum extrusions sub-structures and the high-speed railway vehicle structure.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1996.05a
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• pp.197-205
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• 1996

A combined extrusion process studied here consists of forward and backward extrusion, and it is formed in single operation. The metal flow involved in the operation has appeared to be difficult to analyze accurately because of mixed directions of the flow. In this study, conventional two operations of a forward and a backward extrusions is transformed into one operation of mixed extrusion. A process designed by an industry expert is simulated by the rigid-plastic finite element method to investigate the metal flow and defects. In addition to the FEM simulation, experimental analysis has been carried out to confirm the design in industry, which includes material characterization, preliminary expriment, and whole experimental forming operation. The experimental results show that warm forming of extrusion is more desirable than cold working and hot forming in view of grain growth. Also two conditions of lubrication between workpiece and die has been investigated.

• Journal of the Korean Society for Railway
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• v.15 no.4
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• pp.323-328
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• 2012

The purpose of this study is to develop automated structural design and analysis aided-program of aluminum extrusion carbody structures for railway vehicle. This developed program is called "AUTO-RAP" and could perform simultaneously structural design and verification for railway carbody structures made of aluminum extrusion independent of expertise and experience of design engineers. Design engineers are able to conduct the knowledge-based design by providing database of existing aluminum extrusion or user-defined function. The design verification is automatically programmed to evaluate its structural integrity according to Korean Railway Safety Law or Urban Transit Safety Law. In addition, this program could automatically generate an executable file of various commercial finite element programs such as ANSYS and ABAQUS and CAD files such as .stp and .iges by GUI environment applications using MFC(Microsoft Foundation Classes). In conclusion, it is expected to contribute to reduce product design cost and time of carbody structures aluminum extrusions in railway industry.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.485-488
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• 2005

Most metals are polycrystalline material whose deformation is dominated by the slip system. During the deformation process, orientation of slip systems is rearranged with preferred orientations, leading to deformation-induced crystallographic texture which is called deformation texture. Depending on the texture development, the property of material can be changed. The rate-independent crystal plasticity which is based on the Schmid law as a yield function causes a non-uniqueness in the choice of active slip systems. In this work, to avoid the slip system ambiguity problem, rate-independent crystal plasticity model based on the smooth yield surface with rounded-off corners is adopted. In order to simulate the polycrystalline material under plastic deformation, we employ the Taylor model of polycrystal behavior that all the grains are assumed to be subjected to the macroscopic velocity gradient. Rigid-plastic finite element program based on this rate-independent crystal plasticity is developed to predict the grain-level deformation behavior of FCC metals during metal forming processes. In the finite element calculation, one integration point is considered as a crystalline aggregate which has a number of crystals. Macroscopic behavior of material can be deduced from the behavior of aggregates. As applications, the extrusion processes are simulated and the changes of mechanical properties are predicted.