• 한국자동차공학회논문집
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• 제4권5호
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• pp.16-25
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• 1996

In the present work a rigid-plastic finite element formulation using dynamic explicit time integration scheme is proposed for numerical analysis of auto-body panel stamping processes. The rigid-plastic finite element method based on membrane elements has long been employed as a useful numerical technique for the analysis of sheet metal forming because of its time effectiveness. A damping scheme is proposed in order to achieve a stable solution procedure in dynamic sheet forming problems. In order to improve the drawbacks of the conventional membrane elements, BEAM(abbreviated from Bending Energy Augmented Membrane) elements are employed. Rotational damping and spring about the drilling direction are introduced to prevent a zero energy mode. The lumping scheme is employed for the diagonal mass matrix and linearizing dynamic formulation. A contact scheme is developed by combining the skew boundary condition and the direct trial-and-error method. Computations are carried out for analysis of complicated auto-body panel stamping processes such as forming of an oilpan, a fuel tank and a front fender. The numerical results of explicit analysis are compared with the implicit results with good agreements and it is shown that the explicit scheme requires much shorter computational time, especially when the problem becomes more complicated. It is thus shown that the proposed dynamic explicit rigid-plastic finite element method enables an effective computation for complicated autobody panel stamping processes.

• 한국자동차공학회논문집
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• 제15권2호
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• pp.81-86
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• 2007

We suggest a design method for reducing the number of spot welds in the vehicle body in terms of durability. To reduce the number of spot welds, we use the DOE(Design of Experiments) analysis with two influence indices for the durability and the fatigue life of a spot weld itself. Through the suggested design method, we select spot welds that could be removed without serious reduction of durability of the whole model. We apply this new methodology to the BIW(Body In White) model of a vehicle by choosing some practical parts where durability-related point of view must be considered importantly by experience.

• 한국자동차공학회논문집
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• 제16권1호
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• pp.71-77
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• 2008

This paper proposes an Electronic Throttle Body (ETB) model considering a non-linearity of DC motor driver which is integrated with a H-bridge and a gate driver. A propagation delay and reverse recovery time of switching components cause non-linear characteristic of DC motor driver. This non-linearity affects not only the amateur voltage of DC motor, but also entire behaviour and parameters of ETB. In order to analyze the behavior of ETB more accurately, this non-linear effect of DC motor driver is modeled. The developed ETB model is validated by use of the step response and ramp response experiments, and it shows relatively accurate results compared with linear DC motor driver model.

• 한국자동차공학회논문집
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• 제25권1호
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• pp.1-10
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• 2017

In reverse engineering, one of the main tasks is reconstructing the mechanical properties of used materials. For an isotropic material, it could be defined by a single tensile test using a coupon extracted from the structure. In contrast, CFRP composites require many tests and complex procedures to define all the material properties because CFRP is an orthotropic material and a stacked laminate. In this paper, the procedure to reconstruct composite material properties is studied by using the classical lamination theory and the test data of three different laminates from a composite structure. A sample reconstruction of composite material properties using a composite car body is introduced to verify the method.

• 한국자동차공학회논문집
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• 제11권5호
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• pp.201-209
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• 2003

Virtual human models are widely used to save time and expense in vehicle safety studies. A human model is an essential tool to visualize and simulate a vehicle driver in virtual environments. This research is focused on creation and application of a human model fer virtual reality. The Korean anthropometric data published are selected to determine basic human model dimensions. These data are applied to GEBOD, a human body data generation program, which computes the body segment geometry, mass properties, joints locations and mechanical properties. The human model was constituted using MADYMO based on data from GEBOD. Frontal crash and bump passing test were simulated and the driver's motion data calculated were transmitted into the virtual environment. The human model was organized into scene graphs and its motion was visualized by virtual reality techniques including OpenGL Performer. The human model can be controlled by an arm master to test driver's behavior in the virtual environment.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2003년도 춘계학술대회
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• pp.1166-1172
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• 2003

The extremely strong competition among the world automobile industries has introduced the concept of PLM in the total production activities, one of whose major components is VM(Virtual Manufacturing). If the production lines are equipped with robots, the application of OLP in the virtual space is fully mature. However, in the point of the investment's and the maintenance's view, there are always some activities, which can not be automated: for example, typically the manual welding for prefixing in the automobile body shop and the material loading. Process planning for these activities, therefore, are decided mainly by experiences, which caused many repeated rework of the processes and the inconvenience of the workers, and resulted consequently in the reduction of the productivity and the safety of the workers. In this paper, the optimal dimension of the welding gun and its handle position and the optimal working path is simulated and decided by use of DELIMN/IGRIP and DELMIA/Ergo and the working area modelized in the virtual workcell of DELMIA.

• 한국자동차공학회논문집
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• 제12권4호
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• pp.154-162
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• 2004

In this study, a mathematical model for analyzing the shifting transients of the passenger car with an automatic transmission is proposed. The proposed model comprises a power transmission system and a vehicle system, which are coupled. In order to extract the modeling parameters, on-road car test is carried out. The model is composed of a detailed powertrain, an engine/AT housing, a simplified suspension system, tires and a vehicle body model. On the test, the vehicle accelerations and pitch ratio are measured by using accelerometers and a gyro sensor. The speeds, the brake signal, and the throttle position are taken from sensors which already exist in the vehicle. Considering natural ftequencies, which is calculated from the measured accelerations, and the characteristic equation, vehicle model parameters are identified. Dynamic behaviors during upshift or downshift are simulated using the proposed vehicle model. By comparing and analyzing the simulation result and on-road car test data, the vibration of the Engine/AT housing influences the shifting transients. The effect of model parameters are also studied. Among model parameters, the location of engine mountings influences the vibration of the vehicle body.

• 한국자동차공학회논문집
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• 제14권2호
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• pp.23-31
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• 2006

Tolerance analysis of auto body requires the consideration of its compliance because of potentially significant deformation during the spot-weld assembly process. In this paper, a relatively recent method for such analyses is briefly introduced as one can find in the literature. In this method, it is important to take into account of the covariance between the sources of variation as they are closely located, which is the case in most auto body assembly. However, it is often impossible to know such covariance, for example, when a new car is being developed. Therefore, a mechanics-based method is proposed in this paper to estimate the covariance among the sources of variation by finite element analyses and simple statistical computations. The proposed method is illustrated by applying it to a three-dimensional model of real front wheel housing.

• 한국자동차공학회논문집
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• 제11권4호
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• pp.68-78
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• 2003

Recently, low speed vehicle (LSV) is beginning to appear for various usages. The body of the LSV is usually made of the aluminum space frame (ASF) type rather than the monocoque or unitary construction type. A pa.1 of the reason is that it is easier to reduce mass efficiently while the required stiffness and strength are maintained. A design flow for LSV is proposed. Design specifications for structural performances of LSV do not exist yet. Therefore, they are defined through a comparative study with general passenger automobiles. An optimization problem is formulated by the defined specifications. At first, one pillar which has an important role in structural performances is selected and the reinforcements of the pillar are determined from topology optimization to maximize the stiffness. At second, the thicknesses of cross sections are determined to minimize the mass of the body while design specifications are satisfied. The optimum solution is compared with an existing design. The optimization process has been performed using a commercial optimization software system, GENESIS 7.0.

• 한국재료학회지
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• 제21권7호
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• pp.364-370
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• 2011

Currently, there are two main issues regarding the development of core technologies in the automotive industry: the development of environmentally friendly vehicles and securing a high level of safety in the event of an accident. As part of the efforts to address these issues, research into alternative materials and new car body manufacturing and assembly technologies is necessary, and this has been carried out mainly by the automotive industries. Large press molds for producing car body parts are made of cast iron. With the increase of automobile production and various changes of design, the press forming process of car body parts has become more difficult. In the case of large press molds, high hardness and abrasive resistance are needed. To overcome these problems, we attempted to develop a combined heat treatment process consisting of local laser heat treatment followed by plasma nitriding, and evaluated the characteristics of the proposed heat treatment method. From the results of the experiments, it has been shown that the maximum surface hardness is 864 Hv by the laser heat treatment, 953 Hv by the plasma nitriding, and 1,094 Hv by the combined heat treatment. It is anticipated that the suggested combined heat treatment can be used to evaluate the durability of press mold.