• 한국기계기술학회지
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• 제13권1호
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• pp.105-112
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• 2011

Increasing needs for light weight and high safety in modern automobiles induced the wide application of high strength steels in automotive body structures- The main difficulty in the forming of sheet metal parts with high strength steel is the large amount of springback including sidewall curl and twist in channel shaped member parts- Among these shape defects, twist occurs frequently and requires numerous reworks on the dies to compensate the shape deviation- But until now, it seems to be no effective method to reduce the twist in the forming processes- In this study, a new forming process to reduce the twist deformation during the forming of automotive structural member was suggested- This method consists of forming and restriking of embosses on the sidewall around the stretch flanging area of the part- and was applied in the forming process design of an automotive front side inner member with high strength steel- To evaluate the effectiveness of the method, springback analysis using $Pamstampa^{tm}$ was done- Through the analysis results, the suggested method was proven to be effective in twist reduction of channel shaped parts with stretch flanging area.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 춘계학술대회 논문집
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• pp.302-305
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• 2009

This paper examines the effect of nitride formation on formability for Cu bearing high strength extra low carbon (ELC) steel sheets. For this purpose, we have investigated the effect of addition of aluminium (Al) and boron (B) on texture and precipitation behavior of the ELC steel during continuous annealing. Mechanical properties and microstructures of the ELC steel sheets were analyzed as well using uni-axial tensile test, electron back-scattered diffraction (EBSD) technique and transmission electron microscopy (TEM) following pilot rolling and continuous annealing. It has been found that the addition of Al and B increases the precipitation of AlN and BN. What is more, the scavange of solute nitrogen is effective in increasing the formability of the ELC steels. In addition, the Al and B addition improves the aging property of the ELC steel.

• Journal of Welding and Joining
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• 제18권2호
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• pp.69-76
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• 2000

Formation of the weld defect, such as a blowhole and a pit in lap-jointed fillet arc welds has been a serious problem in arc welding Zn-coated steel sheet. In this study, the relationship among welding conditions, welding materials and defect formation was investigated in order to minimize these defects in the CO₂welds. In addition, the arc stability of the commercial welding wires was evaluated for revealing their effects on defect formation. Main conclusions obtained are as follows: 1) There was no difference between shear tensile strength of the sound welds and that of the welds with blowholes whose diameters are less than 0.5mm. However, the welds with blowholes whose diameters are equal or large than 0.5mm and pits exhibited tensile strength 10∼ 20% and 30∼40% lower than that of the sound welds respectively. 2) The optimum welding condition to effectively prevent or reduce the weld defects formation are as follows: -The welding variables of 220A-23V-100cm/min and 120A-19V-30cm/min were recommended for minimizing the weld defects. -The gap between the two sheets at the lap-joint should be controlled to more than 0.2mm. -Solid wire was less susceptible to the formation of the weld defects than the flux-cored wire. -The low welding current condition produced less weld defects than the high welding current condition. 3) One of the reason why the amount of the defect was reduced at the low welding current was the gas discharging by the active agitation of the molten pool, due to an increasing in the number of the short circuit.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2003년도 추계학술발표대회 개요집
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• pp.18-20
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• 2003

Optimal processing and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from cool rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$ laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• 한국정밀공학회지
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• 제21권7호
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• pp.136-144
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• 2004

Optimal process and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from a cold rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• 한국기계가공학회지
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• 제19권11호
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• pp.102-108
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• 2020

The demand for lightweight materials and high-strength steel has rapidly increased to help reduce the weight of a vehicle body; it improves the fuel efficiency of automobiles and provides passenger safety. Additionally, as the material becomes thinner, the demand for its resistance against corrosion becomes higher. Hence, the application of the surface-treated steel sheet has surged rapidly. In this study, a weld bonding experiment using a delta spot welding machine is performed on a thin sheet of a different material (Al6061-T6/GA440). The thickness of the material was kept at 1 mm to reduce the weight of the automobile body parts. Additionally, the purpose of this study is to control the heat input by applying the welding conditions of a multi-stage pressure pattern to improve corrosion resistance shear strength. The analysis of nugget diameter measurement, shear tensile test, and salt spray test was performed to achieve the aim.

• 소성∙가공
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• 제12권8호
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• pp.702-709
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• 2003

In the automotive industry hydroforming of sheet metal pairs have received special attention because materials for various sheet metal components of vehicles have changed into the high strength steel, aluminum, and titanium blank having low formability. Uniform deformation over the whole region is a main advantage in the sheet hydroforming process. Because upper and lower parts could be produced simultaneously with one tool, hydroforming of sheet metal pairs is competitive in reducing the lead-time and development cost. In this paper, the multi-stage hydroforming process of sheet pair is proposed in order to increase the formability of a structural part like the oil pan shape. The upper die for forming oil pan shape is divided into two parts which can move separately. By the finite element simulation, the design parameters such as geometry of the tool and detailed specification of hydraulic pump were calculated and verified. For the strict comparison of the proposed process, the blank holding force is kept to a constant value during deformation by hydraulic valve. The deformed shape and strain distribution of the manufactured parts with the proposed process are compared with the results of simulation. In the multi-stage hydroforming process, maximum thickness strain was improved by more than 30 percent.

• Steel and Composite Structures
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• 제34권1호
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• pp.91-105
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• 2020

Steel-concrete composite beam with profiled steel sheet has gained its popularity in the last two decades. Due to the ageing of these structures, retrofitting in terms of flexural strength is necessary to ensure that the aged structures can carry the increased traffic load throughout their design life. The steel ribs, which presented in the profiled steel deck, limit the use of shear connectors. This leads to a poor degree of composite action between the concrete slab and steel beam compared to the solid slab situation. As a result, the shear connectors that connects the slab and beam will be subjected to higher shear stress which may also require strengthening to increase the load carrying capacity of an existing composite structure. While most of the available studies focus on the strengthening of longitudinal shear and flexural strength separately, the present work investigates the effect of both flexural and longitudinal shear strengthening of steel-concrete composite beam with composite slab in terms of failure modes, ultimate load carrying capacity, ductility, end-slip, strain profile and interface differential strain. The flexural strengthening was conducted using carbon fibre reinforced polymer (CFRP) or steel plate on the soffit of the steel I-beam, while longitudinal shear capacity was enhanced using post-installed high strength bolts. Moreover, a combination of both the longitudinal shear and flexural strengthening techniques was also implemented (hybrid strengthening). It is concluded that hybrid strengthening improved the ultimate load carrying capacity and reduce slip and interface differential strain that lead to improved composite action. However, hybrid strengthening resulted in brittle failure mode that decreased ductility of the beam.

• 소성∙가공
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• 제17권4호
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• pp.249-256
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• 2008

Combined phase transformation and heat transfer was considered on the simulation of hot press forming process, using material properties modeler, $JMatPro^{(R)}$ and a finite element package, $DEFORM^{TM}$-HT. In order to obtain high temperature mechanical properties and flow curves for different phases, a material properties modeler, $JMatPro^{(R)}$ was used, avoiding expensive and extensive high temperature materials tests. The results successfully show that the strength of hot press forming parts may exhibit different strength in the same parts, depending on the contact of blank with tooling. It was also shown effectively that the strength of the parts can be controlled by designing appropriate cooling paths and coolants. This was shown in terms of different heat convection coefficient in the calculation. Overall, current combination of software was shown to be an effective tool for the tool and process design of hot forming process, although the material modeler needs to be additionally verified by an appropriate set of high temperature materials test.

• Journal of Welding and Joining
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• 제33권3호
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• pp.75-80
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• 2015

Self-piercing riveting is an joining method of advanced high strength steels (AHSS) and other dissimilar materials. It has attracted considerable interest from the automotive industry. The SPR has become an interesting alternative joining technique for difficult to weld materials such as steels and aluminium alloys. In this paper, self-piercing rivet and anvil for SPR were designed for the joining conditions with AHSS and aluminium alloy. Various conditions of SPR were simulated for the design of rivets and anvils. The simulated results were in good agreement with experimental ones. As a result, over HV500 rivet is desirable to joint SPFC780 AHSS and aluminum alloy.