• Composites Research
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• v.22 no.6
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• pp.13-17
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• 2009

This paper decided the 3D shape of sandwich composite for the cradle of CT instrument, suggested the stacking sequence with satisfaction on structural criteria using the Finite Element Analysis, and introduced the manufacturing method to meet the X-ray transmission performance uniformly. The design of Cradle was considered the space between other parts, fixing method, and assembly condition with headrest part. It is decided the stacking sequence to meet the criteria that the deflection at the end point is less than 20 mm when it is applied to 135 kg load at the specific locations. In site of manufacturing method, at first, it is used the hand lay-up for carbon UD and carbon fabric/polyester resin, but it had the ununiform X-ray transmission performance due to the void and excess resin. For solving this problem, it was replaced with the infusion method for the first layer of face material and the application of carbon UD or fabric/epoxy resin prepreg for other layers. Therefor, the property of X-ray transmission was improved.

• Journal of the Korean Society for Railway
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• v.12 no.6
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• pp.859-864
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• 2009

When the vehicle passes through turnout, the design is required to minimize the change of lateral force. Therefore, in case the vehicle passed the through turnout, we ought to execute dynamic analysis of the interaction between the vehicle and turnout in order to make an estimate of the lateral force and the derailment coefficient on the turnout. In this paper, we established the analytical model of the vehicle and turnout and analysed running safety when the vehicle passes through turnout in order to improve running safety of the vehicle on turnout. Also, to verify the vehicle and turnout model, we analysed reaction force and running behavior between wheel and rail, and running safety of the vehicle by changing cradle part and the tongue rail when the vehicle passes through turnout.

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.1
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• pp.86-92
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• 2008

Recently, the use of tubes in the manufacturing of the automobile parts has increased and therefore many automotive manufactures have tried to use hydro-forming technology. The hydro-forming technology may cause many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower spring-back, improved strength and durability and design flexibility. In this study, the whole process of front engine cradle (or front sub-frame) parts development by tube hydro-forming using steel material having tensile strength of 440MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydro-formability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape on automotive sub-frame by hydro-forming process were carefully investigated. Overall possibility of hydro-formable sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydro-forming. At the die design stage, all the components of prototyping tools are designed and interference with press is examined from the point of geometry and thinning.

• Transactions of the Korean Society of Automotive Engineers
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• v.17 no.2
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• pp.98-103
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• 2009

The environment and energy related problem has become one of the most important global issues in recent years. One of the most effective ways of improving the fuel efficiency of automobiles is the weight reduction. In order to obtain this goal the hydroforming technology has been adapting for the high strength steel and its application is being widened. In present study, the chassis components (mainly cross members of engine cradle) simulation and development by hydroforming technology to apply high strength steel having tensile strength of 440 MPa grade is studied. In the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydroformability in details. Overall possibility of hydroformable chassis parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, performing and hydroforming. In the die design stage, all the components of prototyping tool were designed and interference with press was investigated from the point of geometry and thinning.

• Journal of the Korean Society of Systems Engineering
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• v.7 no.1
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• pp.53-56
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• 2011

Configuration management plays a key role in systems engineering process for any project from earlier stage of development. It consists of five major activities, ie., configuration management planing, configuration identification, configuration control, configuration status accounting and configuration verification and audit, and is essential to control system design, development and operation throughout entire life cycle of the system development. And it is directly associated with other part of systems engineering management process, ie., technical data management which provides traceability of important decisions and changes during development. In this paper, we describe how to apply CASE(Computer-aided Systems Engineering) tool-Cradle for the configuration management to achieve effectiveness of Technical Management process.

• Proceedings of the KIEE Conference
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• 2006.07b
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• pp.1095-1096
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• 2006

Configuration management plays a key role in systems engineering process for any project from earlier stage of development. It consists of five major activities, ie., configuration management planing, configuration identification, configuration control, configuration status accounting and configuration verification and audit, and is essential to control system design development and operation throughout entire life cycle of the system development. And it is directly associated with other part of systems engineering management, ie., technical data management which provides traceability of important decisions and changes during development. In this paper, we describe how to apply CASE(Computer-aided Systems Engineering) tool-Cradle for the configuration management to achieve effectiveness of City Train Standard Specification Management process.

• Transactions of Materials Processing
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• v.17 no.1
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• pp.52-58
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• 2008

Tube hydroforming process is generally consisted with pre-bending, preforming and hydroforming processes. Among forming defects which may occur in tube hydroforming such as buckling, wrinkling and bursting, the wrinkling and bursting by local instability under excessive tensile stress mode were mainly caused by thinning phenomenon in the manufacturing process. Thus the accurate prediction and suitable evaluation of the thinning phenomenon play an important role in designing and producing the successfully hydroformed parts without any failures. In this work, the formability on hydroformed part for automobile, i.e. engine cradle, was evaluated using finite element analysis. The initial tube radius, loading path with axial feeding force and internal pressure, and preformed configuration after preforming process were considered as the dominant process parameters in total tube hydroforming process. The effects on these process parameters could be confirmed through the numerical experiments with respect to several kinds of finite element simulation conditions. The degree of enhancement on formability with each process parameters such as initial tube radius, loading path and preform configuration were also compared. Therefore, it is noted that the evaluation approach of the formability on hydroformed parts for lots of industrial fields proposed in this study will provide one of feasible methods to satisfy the increasing practical demands for the improvement of the formability in tube hydroforming processes.

• Proceedings of the KSR Conference
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• 2008.06a
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• pp.1505-1510
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• 2008

A railway is a complex system integrated with a lot of technical elements such as trains, track facilities, human factors, operation & control and maintenance. As a mass transportation system, a railway could contain potential risks that may result in a high death rate and property losses. Accordingly, Railroad Safety Technology R&D Corps. is adopting the plan of the construction of Railway Safety Test Facilities as a part of the Railway Total Safety Project to enhance the railway safety, and carrying out researches on effective project management methods with Systems Engineering techniques. Recently, various systems engineering tools such as CORE or Cradle are applied to manage the system requirements and the project management process in the part of the aerospace engineering and automobile engineering so on. The railway industry also makes an effort to develop an efficient management skills using systems engineering tools as the railway system is multi-disciplinary. Therefore, we propose the more effectual management method of constructing the Railway Safety Test Facilities applying the systems engineering tool to the research.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.8
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• pp.833-838
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• 2007

In tube hydroforming process, several defective products could be obtained such as bursting, wrinkling, folding, buckling. Because, especially, bursting is most frequently occurred failure among the well known failures, it is mostly important to predict the onset of bursting failure on tube hydroforming process. For most sheet metal forming processes, strain based forming limit diagram(FLD) is used often as a criteria to estimate the possibility of onset of the failures proposed above. However, FLD has a shortcoming that it is dependent on strain path while stress based diagram is independent on strain history. Generally, tube hydroforming consists of three main processes such as pre-bending, pre-forming, and hydroforming and it means that the strain histories of final products are nonlinear. Therefore, forming limit stress diagram(FLSD) is more suitable to predict forming limit for hydroforming parts. In this study, FLSD is applied to estimate bursting failure for an engine cradle of an automobile part. Consequently, it is proved that application of FLSD to predict forming limit is available for tube hydroforming parts.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.187-190
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• 2009

Recently, automotive companies have invested in vehicle weight reduction and clean car development because of oil price rises and environmental problems. In particular, USA car makers have developed the vehicle spending 1 liter per 34km complying with PNGV(Partnership for a new generation of vehicle) and Europe car makers have developed the vehicle spending 3 liters per 100km. The USA government announced "The green car policy" in order to boost production of more fuel effective cars in 2009. According to the policy, it will be restricted to sell the car which spends more than 1 liter per 14.9km by 2020. To satisfy the current situations on automotive market, hydroforming technology has widely adapted vehicle structures such as engine cradle, chassis frame, A pillar, radiator support, etc. However, automotive companies have to consider formability and performance to improve and maximize the benefit from this technology in advance of detail design. The paper deals with one of the vehicle weight reduction methods using tube hydroforming technology and platform commonality in front suspension. FEA simulation is also introduced to evaluate hydro-formability and NVH performance at the beginning of design stage which is the best way to reduce the failure cost.