• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 추계학술대회 논문집
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• pp.241-244
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• 2008

Automotive companies have conducted a study for light weigh body and crash safety. But It is difficult to adapt a mass production because of formability with high strength steel in the conventional stamping process. Recently, Automotive maker in the Europe, USA, Japan has applied a hot stamping with boron steel in the body structure. Hot stamping technology spread fast in various body parts of automobile. Bumper beam has been applied in the foreign automotive company so much nowadays. In this study, We will optimize crash performance of bumper beam using hot stamping through comparison with conventional bumper beam.

• 대한기계학회논문집A
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• 제34권1호
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• pp.1-9
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• 2010

본 연구의 목적은 저속충돌에서 승용차량의 범퍼체결구조를 분석하기 위한 것이다. 차량의 손상성-수리성 향상 연구를 위해 범퍼체결구조가 서로 상이한 3개 차종에 대해 RCAR(세계자동차 수리기술위원회)의 저속충돌시험(전,후면 40% 오프셋 충돌시험) 기준을 적용하였다. 시험결과 충격흡수능력은 직사각형 단면형상을 가지고 그 부분이 범퍼레일에 삽입되는 크래시박스식의 범퍼스테이가 대부분의 차량에 적용되고 있는 다른 두 유형의 범퍼체결구조에 비해 우수하게 나타났다. 우수하게 설계된 직사각형 단면형상을 가지는 범퍼체결구조가 저속충돌사고 시 차량의 손상성-수리성을 향상시킴으로써 승객의 안전성도 강화시킬뿐만 아니라 수리비 절감에도 기여할 수 있다는 것이 본 연구에서 입증되었다.

• International Journal of Automotive Technology
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• 제7권2호
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• pp.209-216
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• 2006

A study has been conducted for an optimal processing and an apparatus for manufacturing a laser welded tube for one-body formed bumper beam. The tube dimensions used in calculation were the thickness of 1.4 mm, the diameter of 105.4 mm and the length of 2000 mm. The tube was formed of a cold rolled high strength steel plate(tensile strength of 600 MPa). The two-roll bending method was the optimal tube forming process in comparison with the UO-bending method, the bending method on the press brake, the multi-step continuous roll-forming method and the 3-roll bending method. Monitoring of the welding quality was conducted and the seam tracking along the butt-joint lengthwise to the tube axis was also examined. The longitudinal butt-joint was welded by using a $CO_2$ laser welding machine equipped with a seam tracker and a plasma sensor. The $CO_2$ laser tube welding machine could be used for precise seam tracking and real-time monitoring of the welding quality. As a result, the developed laser welded tube could be used for a one-body formed automobile bumper beam.

• 한국정밀공학회지
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• 제21권7호
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• pp.136-144
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• 2004

Optimal process and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from a cold rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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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.

• 한국자동차공학회논문집
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• 제10권6호
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• pp.125-132
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• 2002

Bumpers are structural components to reduce physical damage to the front and rear ends of a passenger motor vehicle from low speed collisions. Damage assessment and the protectiveness are the commonly used designing criteria but in this study, relative displacements of the bumper are examined. To absorb the crash energy without significant damage to the bumper itself, foam material is installed between fascia and beam. However, it is not easy to predict the exact displacements generated in bumper structures through FEM because the compressive stress-strain curve of a foam material depends on strain rates that deviates significantly on each trial. Under this uncertain condition, a range of displacements is calculated and the optimum design is performed using the design of experiments. The result will be used to find the design that minimizes the weight within displacement constraints. The orthogonal array of L9 is introduced to find the optimum of the design variables that considers the thickness of inner beam, outer beam and stay, This study will suggest the design procedure of a front bumper using the uncertain stress-strain curve of a foam material.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 춘계학술대회 논문집
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• pp.357-358
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• 2006

Importance of using an injection molding analysis has been increased. However the application of it has not been increased because the results of analysis do not sometime match to practical molding. Therefore, the difference of flow analysis and practical molding should be decreased. This study presents reasons of the difference for the location of weld-line in the flow analysis and practical molding on automobile bumper molding.

• 한국자동차공학회논문집
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• 제10권4호
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• pp.206-215
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• 2002

It is to be classified into friendly environment and safety problems, as a main technology development of the recent automotive industry. As these tendency, lots of automobile companies focus on a reduction of fuel expenses and strengthen of crash safety using high strength steel. In this study advanced technologies such as tailored blanks, aluminum extrusion and high strength steel forming applied to bumper beam will be described. As a result of impact analysis and an actual impact test, in terms of beam performance and a possibility fur the mass production will be discussed.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2005년도 춘계학술대회 논문집
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• pp.109-114
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• 2005

The large injection molded parts technology such as instrument panel, front and rear bumper are presented for a precision molding. Some lead time and cost are required to product these part from design to mass product. Recently, CAE is widely used in product design, mold design and analysis of molding conditions to reduce time and cost. The optimal molding conditions can be obtained by DOE(Design of Experiment). The optimal design applications with CAE and DOE have been used in small molded parts. However, application to the large molded body is not reported. In this paper, optimization of injection molding process is studied for quality control in mass production of automobile bumper. Mold temperature difference is chosen through robust design of injection molding process, the molding process being optimized in term of shrinkage and deflection. The optimal conditions through DOE are validated by using injection molding analysis.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2008년도 추계학술대회A
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• pp.1156-1161
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• 2008

Nonlinear dynamic analysis is generally used in automobile crash analysis and structural optimization considering crashworthiness uses the results of nonlinear dynamic analysis. Automobile crash optimization has high nonlinearity and difficulty in calculating sensitivity. Recently the equivalent static load (ESL) method has been proposed in order to overcome these difficulties. The ESL is the static load set generating the same displacement field as the nonlinear dynamic displacement field at each time step in dynamic analysis. From various researches regarding the ESL method, it has been proved that the ESL method is fairly useful. The ESL method can mathematically optimize a crash optimization problem through nonlinear analysis and well developed static optimization. The ESL is applied to nonlinear dynamic structural optimization of the automobile frontal impact problem. An automobile bumper is optimized. The mass of the structure is minimized while some constraints are satisfied.