• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.53-57
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• 2002

Brake tube is considered one of the most important parts in automobile. The shape of brake tube-end has a great influence on the function of brake, and the quality and productivity of brake tube have relation to die design. The forming process of brake tube-end is peformed by hydraulic press forming machine. In this paper, the forming processes of tube-end for automobile is analyzed and designed to make the optimal form of brake tube-end. Also, finite element analysis has been carried out using DEFORM-3D$\^$TM/ to predict the optimal shape of brake tube-end and the results obtained showed the optimal length between punch and chuck is 1.0 ∼ 1.2mm. The shape of tube-end is in good agreement with the finite element simulations and the experimental results.

• Journal of Power System Engineering
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• v.6 no.3
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• pp.31-35
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• 2002

Brake tube is considered one of the most important parts in automobile. The shape of brake tube end has a great influence on the function of brake, and the quality and productivity of brake tube have relation to die design. The forming process of brake tube end is performed by hydraulic press forming machine. In this paper, the forming processes of tube end for automobile is analyzed and designed to make the optimal form of brake tube end. Also, finite element analysis has been carried out using $DEFORM^{TM}% 3D to predict the optimal shape of brake tube end and the results obtained showed the optimal length between punch and chuck is $1.0{\sim}1.2mm$. The shape of tube end is in good agreement with the finite element simulations and the experimental results.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.1
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• pp.113-119
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• 2008

The purpose of the present paper is to investigate the optimal shape of the brake tube-end and flare nut for automobiles using the $DEFORM^{TM}-3D$, finite element code. A flare nut is a small and important part used to join a brake tube-end in automobiles. In this instance, we studied the optimal forging processes for the tube-end and flare nut. Finite element analysis has been carried out to predict an optimal shape of the tube-end and flare nut. Also the simulation results were reflected to the forging processes design for the tube-end and flare nut. The shape of the tube-end and flare nut is in agreement with the finite element simulation and the test results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.155-160
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• 2008

End part of the brake tube formed with the shape of snake head is important for the braking of automobile in safety because it has to prevent crack, fracture and defects occurred during the forming process. Especially, the shape of tube end has influence on the ability of brake. Based on the procedure of process design, in this paper, the forming operation is done by finite element method and the design variables are analyzed by Taguchi method. Design variables such as the outer angle of tube end with the shape of snake head(A), the inner angle to make a hole at tube end with the shape of snake head(B) and the forming distance at tube end(C) are used. Optimization of design variables is performed to minimize the damage factor of the tube end occurred during the forming process. The value of damage factor of 0.327 was obtained under the optimal condition like $A=114^{\circ},\;B=80^{\circ}$ and C=5.3mm, respectively.

• Journal of Advanced Marine Engineering and Technology
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• v.28 no.1
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• pp.83-89
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• 2004

Flare nut is an important Part that used to joint a brake tube-end in automobiles. It was made of SWCH 10A by machining. But we studied to make it by metal forming. The main focus of this paper is to investigate an optimal forging processes for flare nut using the DEFORM$^{TM}$-3D. commercially available finite element code and tests. Actually an explicit finite element analysis of the flare nut forging processes has been carried out to predict an optimal shape of the flare nut and its results were reflected in the tests of the forging processes design for flare nut. The simulation results which had obtained from finite element analysis were contributed to the forging processes design for flare nut. An optimal shape of nave nut showed agreements with test results. Furthermore. this paper should contribute to a development of the forging process for a variety of parts.s.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.1
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• pp.61-69
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• 2020

This study examined the braking characteristics of a heavy haul freight train with P4a distribution valves applied to domestic high-speed freight trains. A freight train was composed of 50 cars, which is twice the normal operation. A braking test was performed to confirm the characteristics of the braking of a heavy haul. The brake cylinder pressures were measured for emergency and service braking on the 1st, 10th, 20th, 30th, and 50th cars. Because the brake signal is transmitted to the pressure through the braking tube connected to the end of the train, the rear vehicle is braking later than the vehicle ahead. Therefore, it is necessary to predict the brake pressures in all cars in a train to supplement the results of the limited tests and calculate the braking distance. The pressure in each car was determined using empirical models of linear interpolation, stepwise, and exponential models, which provided reliable information. The predictive results of the empirical models were compared with the measured results, and the exponential model was predicted relatively accurately. These results are expected to contribute to the safe operation of heavy haul freight trains and can be used to predict the braking distance and calculate the level of impact between vehicles during braking.