• 소성∙가공
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• 제15권5호
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• pp.387-394
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• 2006

In order to see the effect of die deformation on the forming analysis of sheet metals, the draw-ins, strains, and spring-backs of an automotive fender panels are numerically simulated by considering the die deformation found by the simultaneous structural analysis of press and dies. By coupling the forming analysis and the structural analysis, the die deformation is simultaneously taken into account in the forming process. Furthermore, for the consideration of load difference transferred among the upper die, punch, and blank holder due to the changes in sheet thickness, the gap elements are employed instead of the blank sheet in the structural analysis. The numerical simulation results of an automotive finder draw panel are compared with the measurements. The comparison of the forming and spring-back analysis results between the rigid die and the deformed die shows that the consideration of tool deformation can predict more accurately the forming and spring-back of sheet metals.

• 소성∙가공
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• 제24권2호
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• pp.107-114
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• 2015

The current study presents a geometric measurement and analysis of the section profile for a feature line surface on an automotive outer panel. A feature line surface is the geometry which is a visually noticeable creased line on a smooth panel. In the current study the section profile of a feature line surface is analyzed geometrically. The section profile on the real press panel was measured using a coordinate measuring machine. The section profiles from the CAD model and the real panel are aligned using the same coordinate system defined by two holes near the feature line. In the aligned section profiles the chord length and height of the curved part were measured and analyzed. The results show that the feature line surface on the real panel is doubled in width size.

• 소성∙가공
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• 제23권2호
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• pp.75-81
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• 2014

Progressive dies are used for metal stamping during which multiple operations are performed in a sequence. Material is fed automatically from a coil into the press and advances from one die station to the next with each press stroke. Transfer dies are used in high-volume manufacturing for round, deep-drawn, and medium-to-large parts. Several different operations may be incorporated within a transfer die such as blanking, bending, piercing, trimming, and deep drawing. The main challenge in the current study is how to deform a seat cushion panel meeting the design specifications without any defects. A complex automation die manufacturing technology for the automotive seat cushion panel, mixing both semi-progressive die and transfer die for continuous production, was developed.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.82-85
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• 2005

In order to see the effect of die deformation on the forming of sheet metal, the draw-ins, strains, and springbacks of an automotive fender panels are numerically simulated considering the die deformation found by the simultaneous structural analysis of press and dies. The comparison of the forming analysis result between the rigid die and the deformed die layout shows that the deformed tool provides more accurate forming and springback result.

• 한국생산제조학회지
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• 제22권6호
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• pp.1018-1024
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• 2013

In the process of draw die design for stamping automotive press panels, the addendum surfaces generated in metal forming simulation software cannot be used in downstream processes such as machining and making draw dies because simulation tools use simple discrete models for the surface geometry. The downstream processes require more precise and continuous geometric models such as NURBS surfaces. Generally, automotive die engineers manually regenerate the addendum surface geometry using the discrete model. This paper presents an automated geometric modeling process for generating addendum surfaces using draft surface models. The design parameters of the section curve for the addendum surfaces are extracted automatically from the draft geometry. Using the extracted design parameters, smooth addendum surfaces are generated automatically as NURBS surfaces. The generated surfaces are $G^1$ continuous with the part surface and the binder surface, and can be used in downstream processes.

• 소성∙가공
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• 제24권6호
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• pp.400-404
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• 2015

For mass production of stamped parts, which require complicated in-press operations, it is always advisable to use a progressive die set. It is difficult to choose a progressive die set if the stamped parts need to be deep drawn and especially if they are unsymmetrical. Because unsymmetrical deep drawing parts are very sensitive to the effect of weight during moving to the next step, they are hard to exactly locate on the die face. An automotive seat side cushion panel is about 80mm high, unsymmetrical and its low edge needs hemming, so it is hard to produce even using a progressive die set. In the current paper a progressive stamping for seat side cushion panel was examined. Five strip bridges were considered to be strong enough to move to the next die as predicted by the CAE analysis.

• 열처리공학회지
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• 제23권6호
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• pp.301-308
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• 2010

A steel with chemical composition, 0.22% C, 0.25% Si, 1.26% Mn, 0.22% Cr, 0.04% Ti, 0.0042% B, and a microstructure of ferrite and spheroidized cementite has been press-formed to automotive center pillar followed by local-hardening heat-treatment. Hardness, tensile properties, fractography, microstructure and surface roughness of local-hardening heat-treated automotive center pillar have been examined. The directly heated and quenched area had fully martensitic structure with Vickers hardenss in the range of 500 to 510. The heat affected area close to the directly heated area showed dual-phase structure of ferrite and martensite. The width of the heat-treated and heat-affected areas after the local-hardening heat treatment was ranging from 32 mm to 50 mm. The surface of the local-hardening heat-treated center pillar revealed some temper color as a consequence of the oxidation during the heat treatment, but the surface roughness was not affected by the local-hardening heat treatment.

• 소성∙가공
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• 제25권1호
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• pp.29-35
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• 2016

In the current study, finite element analysis was conducted for the press hemming of automotive panels in order to predict various hemming defects such as roll-in and turn down. The analysis used the exact punch movement based on the cam location and considered the sealer between the inner and outer panels with an artificial contact thickness. The analysis results quantify the hemming defects especially at the flange edge in the matching region of the head lamp. A design of experiments along with the parameter study was used to obtain the optimum process parameters for minimizing hemming defects. The optimization process selects the intake angle, bending angle of the hemming punch, and the flange height of the outer panel. The optimum design process determines an appropriate tool angle and flange height to reduce the roll-in and turn-down as compared to the initial design.

• 오토저널
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• 제3권1호
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• pp.19-26
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• 1981

자동차제조에 있어서의 용접은 신뢰성 양산과 생력화에 대응하여 접합 조립하는 방법으로 특이한 분야를 형성하여 발전되었다. 예를 들면, 자동차의 생산은 기본적으로 양산체제를 갖추고 있 어서, 일반적으로 노동집약형 산업이라고 불리어지며 그 제조공정을 보면 stamping press 공정과 같이 용접공정도 비교적 장치산업적인 분야로 빠르게 자동화나 성인화 내지 무인화로 진행되고 있다. 자동차용접은 사람이 portable spot welder로 한점씩 용접하지만 양산에 대비한 합리화와 안정화를 위하여 다점용접 (multi spot weld)라는 자동화공법의 도입이 불가피하며 금일의 자 동차생산에 있어서 상식화가 되고 있다. 이것은 한개의 차체라면 차형의 대조 또는 press panel의 수에 따라 차이가 조금 있으나 약 4-5 천점의 점용접이 필요하기 때문에 여러 가지 반송장치와 조합하여 대규모의 line설비로 발전되어 가고 있다. 이와 같이 용접공정의 자동화는 생산성을 높이는 반면에 전용성이 높기 때문에 설계변경에 대한 초기투자의 용접설비 대부분을 갱신하여야 하는 새로운 투자의 필요문제가 증대되었다. 이러한 전용설비에 대한 유연성을 가미한 자동차로 지향되어, 그 한 방법으로 산업용 robot가 도입되었다. 근래에 와서는 자동차제조에 있어서 새 로운 용접기술을 합리적으로 효과있게 적용하는 기술이 금후의 연구과제라 하겠다.

• Geomechanics and Engineering
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• 제14권1호
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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.