• Transactions of Materials Processing
• /
• v.32 no.3
• /
• pp.160-165
• /
• 2023

As the supply of eco-friendly vehicles increases, the application rate of hot stamping components is rising to reduce vehicle weight and improve safety. Although Al-Si coated steel sheets are commonly used in hot stamping processes, their manufacturing costs are elevated due to process patents and royalties. Various hot stamping studies have been conducted to reduce these production costs. In this study, we derived a process control method for suppressing the oxide layer of hot stamping parts using uncoated boron steel sheets. Firstly, hat-shaped parts were hot stamped under atmospheric conditions to analyze the tendency of oxide layer formation by location. Then, the Gleeble system was used to observe oxide layer formation based on oxygen content under various atmospheric conditions. Finally, the oxide layer thickness was quantitatively measured using SEM images.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.10a
• /
• pp.42-45
• /
• 2008

Recently, aluminum is widely used to reduce the vehicle weight. Aluminum curved extruded products are used for the design of automotive frame parts. This study focuses on the determination of process condition fur automotive bumper beam with various curvatures. In this study, a curvature prediction model has been proposed considering the geometric relationship and the characteristic of the curvature extrusion equipment. Using the proposed model and FE analysis, the appropriated process condition was determined to produce the bumper beam. Finally, curvature extrusion experiment was carried out to verify the effectiveness of the proposed curvature prediction model and the process condition.

• Journal of Welding and Joining
• /
• v.28 no.3
• /
• pp.92-98
• /
• 2010

Ferritic stainless steels, which have relatively small thermal expansion coefficient and excellent corrosion resistance, are increasingly being used in vehicle manufacturing, in order to increase the lifetime of exhaust manifold parts. But, there are limits on use because of the problem related to cosmetic resistance, corrosions of condensation and high temperature salt etc. So, Aluminum-coated stainless steel instead of ferritic stainless steel are utilized in these parts due to the improved properties. In this investigation, Al-8wt% Si alloy coated 409L ferritic stainless steel was used as the base metal during Gas Tungsten Arc(GTA) welding. The effects of coated layer on the microstructure and hardness were investigated. Full penetration was obtained, when the welding current was higher than 90A and the welding speed was lower than 0.52m/min. Grain size was the largest in fusion zone and decreased from near HAZ to base metal. As welding speed increased, grain size of fusion zone decreased, and there was no big change in HAZ. Hardness had a peak value in the fusion zone and decreased from the bond line to the base metal. The highest hardness in the fusion zone resulted from the fine re-precipitation of the coarse TiN and Ti(C, N) existed in the base metal during melting and solidification process and the presence of fine $Al_2O_3$ and $SiO_2$ formed by the migration of the elements, Al and Si, from the melted coating layer into the fusion zone.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.16 no.4
• /
• pp.81-87
• /
• 2008

In this study, concerns the crashworthiness of the widely used vehicle structure, square thin-walled tubes, which are excellent on the point of the energy absorbing capacity. An experimental investigation was carried out to study the energy absorption characteristics of thin-walled square tubes subjected to dynamic crushing by axial loading to develop the optimum structural members. The impact velocity was tested in the rage $4.698{\sim}8.2m/s$. To efficiently review the collapse characteristics of these sections, the simulation have been carried out using explicit FEM package, LS-DYNA. The solutions compared with results the impact collapse experiment. Here, the controller are introduced to improve and control the absorbed energy of thin-walled square tubes in this paper. To predict and control the energy absorption, we designed it in consideration to the it's influence, height, thickness, wide ratio in this study. When the controller used, the experimental results of crushing of square tubes controlled by the controller's elements showed a good candidate for a controllable energy absorption capability in impact axial crushing.

• Elastomers and Composites
• /
• v.52 no.3
• /
• pp.167-172
• /
• 2017

Ultra-high performance (UHP) tires, for which demand has recently surged, are subject to severe strain conditions due to the low aspect ratio of their sidewalls. It is important to ensure sidewall material durability, since a sudden tire sidewall breakage during vehicle operation is likely to cause a major accident. In the automotive application of rubber parts, cracking is defined as a failure because when cracks occur, the mechanical properties of rubber change. According to Mars, Andre et al., strain and strain energy density (SED) are mainly used as a failure parameters and the SED is generally used as a fatigue damage parameter. In this study, the fatigue life curves of sidewall rubber of tires were determined by using the SED as fatigue damage parameter while the effect of aging on fatigue life was evaluated after obtaining the SED-Nf curves according to aging condition.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.19 no.11
• /
• pp.102-108
• /
• 2020

The demand for lightweight materials and high-strength steel has rapidly increased to help reduce the weight of a vehicle body; it improves the fuel efficiency of automobiles and provides passenger safety. Additionally, as the material becomes thinner, the demand for its resistance against corrosion becomes higher. Hence, the application of the surface-treated steel sheet has surged rapidly. In this study, a weld bonding experiment using a delta spot welding machine is performed on a thin sheet of a different material (Al6061-T6/GA440). The thickness of the material was kept at 1 mm to reduce the weight of the automobile body parts. Additionally, the purpose of this study is to control the heat input by applying the welding conditions of a multi-stage pressure pattern to improve corrosion resistance shear strength. The analysis of nugget diameter measurement, shear tensile test, and salt spray test was performed to achieve the aim.

• Journal of Adhesion and Interface
• /
• v.23 no.4
• /
• pp.101-107
• /
• 2022

Adhesive joints have many advantages such as weight savings, corrosion and fatigue resistance and now developed even withstand of high impact and dynamic loads. However, an adhesion has cumbersome and complicated surface preparation processes. The surface preparation step is critical in adhesive joint manufacturing in order to obtain the prescribed strength for adhesive joints. In this study, it was attempted to simplify and reduce the number of surface preparation steps, and abrasion and rapid adhesive application (ARAA) process is developed for an alternative solution. The abrasion processes are performed only for creating surface roughness in standard procedures (SP), although the abrasion processes cause surface activation itself. The results showed that there is no need the long procedures in laboratory or chemical agents for adhesion. After the abrasion process, the attracted and highly reactive fresh surface layer obtained, and its effect on bonding success is observed and analyzed in this research, in light of the essential physic and adhesion theories. Al 6061 aluminum adherends and epoxy-based adhesives were chosen for bonding processes, which is mostly used in light vehicle parts. The adherends were cleaned, treated and activated only with abrasion, and after the adhesive application the specimens were tested under quasi-static loading. The satisfied ARAA results were compared with that of the specimens fabricated by the standard procedure (SP) of adhesion processes of high impact loads.

• Composites Research
• /
• v.32 no.1
• /
• pp.13-20
• /
• 2019

In this study, in order to improve the quality issue and component characteristics of the battery module, which is one of the major parts of the electric vehicle. The structure is reinforced by using the composite material and the mechanism structure optimization of Hybrid concept which can overcome the disadvantages of single material was performed and the performance was compared. For this purpose, figure out the main design variables of composite materials according to Classical Laminated Plate Theory (CLPT) and the algorithm for predicting composite material properties have been studied. Based on the mechanical properties of the designed composite materials, finite element analysis (FEM) and the performance of the battery module was verified. Consequently, according to the verification result, Hybrid Battery Module reinforced with Selective Composite Patch can reduce the weight by 30% and reduce the product thickness by 32.5% compared with the existing Al battery module and proved the merit of Hybrid structure such as maintaining impact performance.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.21 no.7
• /
• pp.270-276
• /
• 2020

3D printing is an additive manufacturing technology that can produce complex shapes in a single process for a range of materials, such as polymers, ceramics, and metals. Recent 3D printing technology has developed to a level that enables the mass-production through an improvement of the printing speed and the continuous development of applicable materials. In this study, 3D printing technology using a laser was applied to manufacture a heat exchanger for an air compressor in a railway vehicle. First, the optimal design of the heat exchanger was carried out by focusing on weight reduction and compactness as a shape suitable for 3D printing. Based on the design derived, heat exchanger prototypes were made of AlSi10Mg alloy material by applying the SLM technique. Moreover, the manufactured prototypes were attached to an existing air compressor, and the heat exchange performance of the compressed air was tested. The test results of the 3D printed prototypes showed a heat exchange performance of approximately 80% and 85% at low and high-pressure, respectively, compared to the existing heat exchanger. From the 𝓔-NTU method results with an external cooling air condition similar to that of the existing heat exchanger, the calculated heat transfer amount of 3D printed parts showed similar performance compared to the existing heat exchanger. As a result, the 3D printed heat exchanger is lightweight with good performance.