• Journal of the korean Society of Automotive Engineers
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• v.19 no.1
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• pp.3-10
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• 1997

합체 박판을 사용한 생산 방식은 소수의 스템핑 금형 공정으로 인해 전반적으로 공기가 짧아지고, 보다 견고하며 외관상 우수한 차체를 생산할 수 있다. 또한 재료의 수율을 극대화할 수 있을 뿐만 아니라 차체 각부에서 요구되는 성질과 조건에 따라 판 두께나 재질을 대응할 수 있다는 등의 장점을 가지고 있어 초기긔 설비비는 다른 생산 방식에 비해 고가이지만 전체 공정과 장기적인 관점에서 생산비가 절감된다. 본 기고에서는 합체 박판의 생산 및 활용정도와 각 기업체나 연구소들에서의 연구 진척상황, 그리고 앞으로의 전망에 대해 논한다.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.2
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• pp.174-185
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• 2002

The automotive industry faces many competitive challenges including weight and cost reduction to meet need for higher fuel economy. Tailored blanks offer the opportunity to decrease door weight, reduce manufacturing costs, and improve door stiffness. Optimization technology is applied to the inner panel of a door which is made by tailored blanks. The design of tailored blanks door starts from an existing door. At first, the hinge reinforcement and inner reinforcement are removed to use tailored blanks technology. The number of parts and the welding lines are determined from intuitions and the structural analysis results of the existing door. Size optimization is carried out to find thickness while the stiffness constraints are satisfied. The door hinge system is optimized using design of experiment approach. A commercial optimization software MSC/NASTRAN is utilized for the structural analysis and the optimization processes.

• Journal of the Computational Structural Engineering Institute of Korea
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• v.14 no.3
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• pp.277-286
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• 2001

Among the ULSAB methods for the lightweight automobile body, Tailor Welded Blank(TWB) is adopted and the design process is developed for the existing component. Topology optimization conducted to find the distribution of the variable thickness. The number of parts and the welding lines are determined from it. In the detail design, size optimization is carried out to find the optimum thickness of each part and then, the final parting lines are tuned by shape optimization. A commercial optimization software GENESIS is utilized for the optimization processes.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1376-1380
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• 2005

In recent automotive industry, vehicle weight can be reduced by one-step forming of tailored blanks welded with two or more sheets of metal blanks. Tailored blank(TB) welding is a production method for blanks involving welding together materials of different quality, thickness, and coating, and has proved popular in fabrication automotive parts. This paper deals with the forming characteristics of mash seam welded tailored blanks. Using these forming characteristics, the bumper beam was developed using the mash seam welded tailored blank with the different thickness. We performed the forming simulation with respect to strain distribution on blank during the stamping of the bumper rail part. Based on these results, we made some stamping tryouts with selected types of blank designs to investigate the formability of tailored blank with different thickness. During the tryouts, we knew that it was important the BHF(Blank Holding Force). We obtained to reducing 10.5% weight and cost with adapting the bumper beam of automotive component using the tailored blank of mash seam welding.

• 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.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.1
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• pp.125-132
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• 2002

Recently, ULSAB(Ultra Light Steel Auto Body) concept is getting more attention due to various benefits in automotive body design. One of the ULSAB efforts is making a door with TWB(Tailor Welded Blanks). In TWB, two or more patches of steel panels are welded together before stamping process. In this research, domains and thicknesses of the patches in a front door structure are determined by a series of optimization schemes composed of topology, size and shape optimization and DOE(Design of Experiments) scheme. A door is designed to have better performances compared to exiting structure considering static stiffness and natural frequency. The final design is discussed and compared to the existing design.

• Journal of the Korean Society of Mechanical Technology
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• v.13 no.1
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• pp.105-112
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• 2011

Increasing needs for light weight and high safety in modern automobiles induced the wide application of high strength steels in automotive body structures- The main difficulty in the forming of sheet metal parts with high strength steel is the large amount of springback including sidewall curl and twist in channel shaped member parts- Among these shape defects, twist occurs frequently and requires numerous reworks on the dies to compensate the shape deviation- But until now, it seems to be no effective method to reduce the twist in the forming processes- In this study, a new forming process to reduce the twist deformation during the forming of automotive structural member was suggested- This method consists of forming and restriking of embosses on the sidewall around the stretch flanging area of the part- and was applied in the forming process design of an automotive front side inner member with high strength steel- To evaluate the effectiveness of the method, springback analysis using $Pamstampa^{tm}$ was done- Through the analysis results, the suggested method was proven to be effective in twist reduction of channel shaped parts with stretch flanging area.