• Tribology and Lubricants
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• v.31 no.1
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• pp.13-20
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• 2015

The impact beam, a beam-shaped reinforcement installed horizontally between the inside and outside panels of car doors, is gaining importance as a solution to meet the regulations on side collision of vehicles. In order to minimize pelvis injury which is the biggest injury happening to the driver and passengers when a vehicle is subject to side collision, energy absorption at the door impact beam should be maximized. For the inner panel, the thrust into the inside of the vehicle must be minimized. The impact beam should be as light as possible so that the extent of pelvis injury to the driver and passenger during side collision of the vehicle is minimal. To achieve this, the weight of the impact beam, has to be optimized. In this study, we perform a design analysis with a goal to reduce the weight of the current impact design by 30% while ensuring stability, reliability, and comparison data of the impact beam for mass production. We conduct three-point bending stress experiments on conventional impact beams and analyze the results. In addition, we use a side-door collision test apparatus to test the performance of beams made of three (different materials: steel, aluminum, and composite beams).

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.3
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• pp.63-69
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• 2014

This paper studies the strength, fatigue sensitivity, safety factor and lifetimes by means of structural and fatigue analyses of different models of rear doors upon the opening of doors and windows leading to severe fatigue fractures of the window motor components of rear doors. The simulation models were a standard model and other models. The other models, which are denoted here as models I and II, were modified versions of the standard model, with a rib of 3mm and a thickness of 2mm as compared to the standard model. The door was modelled with CATIA V5 and analyzed with the ANSYS program. The material of the rear door was cold rolled steel (DDQ). From the study results, the standard model and model I were confirmed to be less safe upon the opening of the door as compared to the opening of a window in terms of fatigue, but model II was found to be safe for both door and window openings.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.1
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• pp.146-153
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• 2007

Weight reduction for automobile components has been sought to achieve fuel efficiency and energy conservation. There are two approaches in reducing their weights. One is by using material lighter than steel, and the other is by redesigning their structures. The latter has been performed by adopting hydroforming, tailor weled blank, optimization, etc. In this research, the kriging approximation method and simulated annealing algorithm are applied to the design of a front door made by TWB (Tailor Welded Blank) technology. The design variables are set up as the thicknesses of parts and the positions of parting lines. A thickness set considered as a design variable of each part is not arbitrarily determined but selected from standard products, so it is a discrete set. This research presents the discrete and continuous structural optimization method for an automotive door design.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.322-325
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• 2007

Dent resistance is an important characteristic to avoid damage on automotive outer panels. From a practical point of view, dents can be caused in a number of ways. Considering doors as an example, denting can occur from stone impacts or from the careless opening of an adjacently parked vehicle door. Denting can occur where the door surface is smooth and may not have sufficient curvature to resist dent. These exterior body parts are designed to improve dent resistance using a combination of work hardening and bake hardening. In brief, dent is affected by the shape of the parts and the material properties such as yield strength, strain and thickness. In this work, forming of door outer panel is investigated by Taguchi method. Main parameters are yield strength, thickness, blank size, blank holding force and so on. For the given value of design parameters, forming analysis of the thirty six cases are carried out according to L18 orthogonal array. After comparing the performance by simple conversion of simulation results into dent resistance, the final suggestion of the forming parameters is verified for the best improvement of dent resistance.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2000.04b
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• pp.187-194
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• 2000

Weight reduction for an automobile body is being sought for the fuel efficiency and the energy conservation. One way of the efforts is adopting Ultra Light Steel Auto Body (ULSAB) concept. The ULSAB concept can be used for the light weight of an automobile door with the tailor welded blank (TWB). A design process is defined for the TWB. The inner panel of door is designed by the TWB and optimization. The design starts from an existing component. At first, the hinge and inner reinforcements are removed. In the conceptual design stage, topology optimization is conducted to find the distribution of variable thicknesses. The number of parts and the welding lines are determined from the topology design. In the detailed design process, size optimization is carried out to find thickness while stiffness constraints are satisfied. The final parting lines are determined by shape optimization.

• Journal of the Korean Society of Safety
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• v.15 no.1
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• pp.59-65
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• 2000

The purpose of this study is to investigate the details of unsteady heat transfer in a heated fire door. This investigation is carried out numerically for two dimensional fire door which is composed of normal plasterboard and mild steel including air layer or heat shield. It is shown from the results that the recirculation occurs at the inner part of fire wall due to gravity force by temperature difference. The case I gives better adiabatic effect than the case II because temperature around the fire wall reachs at $230.96^{\circ}C$ in the case I and reachs at $450.37^{\circ}C$ in the case II.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.95-101
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• 1998

The steel door inner was manufactured via a new route, tailored blanking process, to remove hinge reinforcement parts, using thicker panels laser welded, instead. It is very important, first of all, in this process, to design optimum configuration of tailored blanks and determine the optimum process control for the stamping. Generally, it was found that the severe deformation reduction behavior during stamping in the thinner panel around weld line caused cracks and the other troubles in formability. It is our purpose of this investigation to introduce how the process control parameters, such as tailored blank configuration, size, location in the die, the position of weld line, BHF, bead configuration, work on the formability. In addition, causes of cracks and movement of weld line after forming were analyzed and compared with computer simulation work.

• 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.

• Proceedings of the Korean Institute of Building Construction Conference
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• 2023.11a
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• pp.155-156
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• 2023

In the case of steel door frames commonly found in general buildings, there are various assembly methods such as rivets, bolts, and welding, but the welding method is generally used. However, this welding joint method has many problems, such as distortion due to heat and damage due to external shock. In particular, when used as a fire door, problems may occur in the event of a fire due to distortion caused by heat from welding and the weak welded joint area. In the case of rivet or welded joints, when moved after assembly, joint loosening due to external shock may occur. Problems may arise where the bonding strength becomes weak. In addition, with the recent increase in high-rise buildings and larger buildings, when assembly is completed and brought to the site, a place is needed to store it, and in addition, there is a problem in that it has to be transported several times in small quantities to the installation site, which is another problem of time and cost loss. This is coming to the fore. In order to fundamentally solve this problem, we have researched and developed a non-welding door frame that can be assembled on site. We have researched and developed three assembly methods: screw-type, insert-type, and protrusion-type. Non-welded door frames are small in size and easy to package, making them advantageous for domestic and overseas exports.