• Transactions of Materials Processing
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• v.20 no.4
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• pp.279-283
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• 2011

Recently incremental sheet metal forming (ISF) has used widely in making prototypes and small-volume products in automotive industry etc. We apply the ISF to make a 1/4 sized automobile body-in-white. First, ISF tests for rectangular shaped cup have been performed to clarify the formability denoting the relationship between the component wall angle and maximum cup height of safe forming. Next, a CAD model for the automobile was designed and segmented into several components in order to accommodate the working space of the CNC machine we adopted and the formability of the sheet metal. Then, a CAM software was employed to generate the tool path for manufacturing wooden dies and all the small parts. Finally, the different parts were joined into a single component by laser welding after the ISF process. By using the ISF we successfully produced the 1/4 sized automobile body-in-white.

• International Journal of Automotive Technology
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• v.1 no.1
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• pp.35-41
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• 2000

The crashworthiness of vehicles with finite element methods depends on the geometry modeling and the material properties. The vehicle body structures are generally composed of various members such as frames, stamped panels and deep-drawn parts from sheet metals. In order to ensure the impact characteristics of auto-body structures, the dynamic behavior of sheet metals must be examined to provide the appropriate constitutive relation. In this paper, high strain-rate tensile tests have been carried out with a tension type split Hopkinson bar apparatus specially designed for sheet metals. Experimental results from both static and dynamic tests with the tension split Hopkinson bar apparatus are interpolated to construct the Johnson-Cook and a modified Johnson-Cook equation as the constitutive relation, that should be applied to simulation of the dynamic behavior of auto-body structures. Simulation of auto-body structures has been carried out with an elasto-plastic finite element method with explicit time integration. The stress integration scheme with the plastic predictor-elastic corrector method is adopted in order to accurately keep track of the stress-strain relation for the rate-dependent model accurately. The crashworthiness of the structure with quasi-static constitutive relation is compared to the one with the rate-dependent constitutive model. Numerical simulation has been carried out for frontal frames and a hood of an automobile. Deformed shapes and the Impact energy absorption of the structure are investigated with the variation of the strain rate.

• International Journal of Automotive Technology
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• v.7 no.7
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• pp.853-858
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• 2006

The method of die-face design based on the CAE platform for automobile panels can fast modify the die addendum. In contrast with the process of the die-face design based on the CAD platform, there are some special steps for the die-face design based on the CAE platform. The most obvious difference is that the auto-body part contour needs smoothing arlier than the design of addendum surfaces does. It is helpful to improve the design quality of addendum surface. In spite of extensive researches on the smoothing technique, here is still dearth of the published solutions about smoothing the part contour with additional surface. This paper attempts to analyze the difficulties and provides practical solutions. Main results include the algorithm to calculate the segments needing to be smoothed on boundary, the strategy to create the smoothing curve and the procedure of surface generation. The relevant function modules for parametric design are developed. A few examples and suggestions for future work conclude the paper.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.5
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• pp.214-222
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• 2002

Computer simulations are widely used to analyze passenger safety in simulated traffic accidents. ATB, Articulated Total Body, is a computer simulation model developed to predict gross human body response to such dynamic environments as vehicle crashes and pilot ejections. ATB, whose code is open, has high flexibility and application capability that users can easily insert defined modules and functions. ATB is, however, inconvenient as it was coded in FORTRAN and it needs a formated input file. Moreover, it takes much time to make input files and to modify coding errors. This study aims to increase user friendliness by adding a preprocessor program, WINATB(WINdows ATB), to the conventional ATB. WINATB, programmed in Visual C＋＋ and OpenGL, uses ATB IV as a dynamic solver. The preprocessor helps users prepare input files through graphic interface and dialog box. An additional postprocessor makes the graphical presentation of simulated results. In these case of the frontal crash, the rear impact and the side impact, the simulation results obtained by WINATB and MADYMO(MAthematical Dynamic Model) are compared to validate the effectiveness of WINAIB.

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.4
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• pp.97-102
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• 2008

The vibration of a vehicle, which is caused by and transmitted from the engine, has significant effect on the ride comfort and the dynamic characteristics of the engine mount system have direct influence on the vibration and noise of the vehicle. This paper examines the body shake caused by the engine excitation force on engine key on/off of a medium truck by experiment and simulation. The analysis model consists of the engine, a body including the frame, front and rear suspensions and tires. The force element between the body and the suspension is modeled as a combination of a suspension spring and a damper. The engine shake obtained from the experiment was compared with the result of the computer simulation, and by using the verified computer model, parametric study of the body shake on engine key on/off is performed with changing the stiffness of an engine mount rubber, the engine mount angle, and the position of engine mounts.

• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.2
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• pp.31-38
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• 2010

Bus manufacturers have tested and studied the dynamic collapse behavior of a bus body structure in rollover since UN ECE established ECE Regulation 66 to provide the requirement for the strength of bus structure. In spite of the costly cycles of practical tests, however, it is still a hard task to meet the rollover regulation by means of local reinforcements in the bus structure. Therefore it is necessary to develop a well designed strategy for the rollover strength implemented in the early stage of vehicle development. In this study, the suitable development method for each design stage from a component to complete body structure was considered to make a well-established development process of a bus body structure for rollover safety. For the efficient approach of the concept design stage, a numerical model based on the plastic hinge theory was used instead of detailed shell models. After setting up the concept design for the component size and geometry, the shell model was used to confirm and optimize the whole structure composition. The process developed in this study was practically used as an effective method to predict the rollover behavior of a new bus body structure.

• Journal of Powder Materials
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• v.22 no.3
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• pp.197-202
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• 2015

In this study, porous stainless steel (STS316L) sintered body was fabricated by powder metallurgy method and its properties such as porosity, compressive yield strength, hardness, and permeability were evaluated. 67.5Fe-17Cr- 13Ni-2.5Mo (wt%) powder was produced by a water atomization. The atomized powder was classified into size with under $45{\mu}m$ and over $180{\mu}m$, and then they were compacted with various pressures and sintered at $1210^{\circ}C$ for 1 h in a vacuum atmosphere. The porosities of sintered bodies could be obtained in range of 20~53% by controlling the compaction pressure. Compressive yield strength and hardness were achieved up to 268 MPa and 94 Shore D, respectively. Air permeability was obtained up to $79l/min{\cdot}cm^2$. As a result, mechanical properties and air permeability of the optimized porous body having a porosity of 25~40% were very superior to that of Al alloy.

• Geomechanics and Engineering
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• v.14 no.1
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• pp.91-98
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• 2018

Length of a vehicle is an important variation to generate different variants of an automotive platform. This parameter is usually adjusted by embedding dimensional flexibility into different components of the Body in White (BIW) including the floor pan. Due to future uncertainties, it is not necessarily possible to define certain values of wheelbase for the future products of a platform. This work is performed to add flexibility into the design process of a length-variable floor pan. By means of this analysis, the cost and time consuming process of optimization is not necessary to be performed for designing the different variants of a product family. Stiffness and mass of the floor pan are two important functional requirements of this component which directly affect the occupant comfort, dynamic characteristics, fuel economy and environmental protection of the vehicle. A combination of Genetic algorithm, GMDH-type of artificial neural networks and TOPSIS methods is used to optimally design the floor pan associated with arbitrary length of the variant in the defined system range. The correlation between the optimal results shows that for a constant mass of the floor pan, the first natural frequency decreases by increasing the length of this component.

• International Journal of Automotive Technology
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• v.6 no.1
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• pp.71-77
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• 2005

This paper presents a systematic approach which determines the optimal period to minimize performance measure subject to the schedulability constraints of a real-time control system by formulating the scheduling problem as an optimal problem. The performance measure is derived from the summation of end-to-end response times of processed I/Os scheduled by the static cyclic method. The schedulability constraint is specified in terms of allowable resource utilization. At first, a uniprocessor case is considered and then it is extended to a distributed system connected through a communication link, local-inter network, UN. This approach is applied to the design of an automotive body control system in order to validate the feasibility through a real example. By using the approach, a set of optimal periods can easily be obtained without complex and advanced methods such as branch and bound (B&B) or simulated annealing.

• Journal of the korean Society of Automotive Engineers
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• v.15 no.1
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• pp.107-119
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• 1993

The objective of this study is to analyze the static and dynamic characteristics of automotive rubber components by computer simulation. Bush / rectangular type engine mounts and wind shield weather strip are analyzed by using the commercial code ABAQUS and the results are verified by experiments. Large deformation static response is analyzed in order to get the information about the deformation pattern and static stiffness of engine mounts, and about the seperation force of wind shield weather strip from body. The isothermal steady-state dynamic response of components which have been subjected to an initial static pre-load is analyzed for the dynamic stiffness of engine mount rubber components. There are good agreements between simulation and experiments. So it is possible to apply the computer simulation to the design of automotive rubber components.