• Journal of Auto-vehicle Safety Association
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• v.13 no.4
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• pp.26-32
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• 2021

This study is intended to augment the Roof strength test being evaluated by IIHS (Insurance Institute for Highway Safety). In order to find solutions for increasing Roof Crashworthiness Evaluation SWR (Strengthto-weight ratio). This study introduces that Integrated Connection Structure Between Center Pillar and Roof Center Rail is proposed as a critical solution.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.895-896
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• 2012

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2013.05a
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• pp.1161-1162
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• 2013

• Transactions of Materials Processing
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• v.32 no.6
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• pp.311-320
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• 2023

Recently, lightweight of automotive parts has been required to solve environmental problems caused by global warming. Accordingly, research and development are proceeded on manufacturing of parts using aluminum that can replace steel for lightweight of the automotive parts. In addition, high strength aluminum can be applied to body parts in order to meet both requirements of lightening and improving crash safety of vehicle. In this study, hot blow forming of roof side rail is employed to manufacturing of the automotive parts with high strength aluminum tube. In hot blow forming, longer forming times and excessive thinning can be occurred as compared with conventional manufacturing processes. So optimization of process conditions is required to prevent excessive thinning and to uniformize thickness distribution with fast forming time. Mechanical properties of high strength aluminum are obtained from tensile test at high temperature. These properties are used for finite element(FE) analysis to investigate the effect of strain rate on thinning and thickness distribution. Variation of thickness was firstly investigated from the result of FE analysis according to tube diameter, where the shapes at cross section of roof side rail are compared with allowable dimensional tolerance. Effective tube diameter is determined when fracture and wrinkle are not occurred during hot blow forming. Also FE analysis with various pressure-time profiles is performed to investigate the their effects on thinning and thickness distribution which is quantitatively verified with thinning factor. As a results, optimal process conditions can be determined for the manufacturing of roof side rail using high strength aluminum.

• Proceedings of the KSR Conference
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• 2005.11a
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• pp.338-343
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• 2005

We have evaluated the structural integrity of a sandwich composite train roof which can find a lightweight, cost saving solution to large structural components for rail vehicles in design stages. The sandwich composite train roof was 11.45 meter long and 1.76 meter wide. The reinforced frame was inserted in sandwich panels to improve the structural performance of train roof structure and had the shape of hollow rectangular box. The finite-element analysis was used to calculate the stresses, deflections and natural frequencies of the sandwich composite train roof against the weight of air-condition system. The 3D sandwich FE model was introduced to simulate the hollow aluminum frames which jointed to both sides of the sandwich train roof. The results shown that the structural performance of a sandwich composite train roof under load conditions specified was proven and the use of aluminum reinforced frame was beneficial with regard to weight savings in comparison to steel reinforced frame.

• Proceedings of the KSR Conference
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• 1999.11a
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• pp.437-446
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• 1999

The structural behavior of the composite material light rail vehicle body are investigated. Composite material is very useful for light rail vehicle structure due to its high specific strength and lightweight characteristics. The main carbody is made of aluminum alloy. The side wall and roof with composite panels can reduce total vehicle weight about 2000kg. In addition, with the lower density of the foam, enhances lightness in the panel and to save the operation expenses. The finite element analysis code, ANSYS is used to evaluate the stability of the body structure under the various load conditions.

• Journal of the Korean Society for Railway
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• v.9 no.1 s.32
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• pp.43-49
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• 2006

We have evaluated the structural integrity of a sandwich composite train roof structure that can be a lightweight, cost saving solution to large structural components for rail vehicles in design stages. The sandwich composite train roof structure was 11.45 meters long and 1.76 meters wide. The finite element analysis was used to calculate the stresses, deflections and natural frequencies of the sandwich composite train roof against the weight of air-conditioned system. The 3D sandwich finite element model was introduced to examine the structural behavior of the hollow aluminum extrusion frames joined to both sides of the sandwich composite train roof. The results shown that the structural performance of the sandwich composite train roof under loading conditions specified is satisfaction and the use of aluminum reinforced frame and aluminum honeycomb core is beneficial with regard to weight saving and structural performance in comparison with steel reinforced frame and polyurethane foam core. Also, we have manufactured prototype of sandwich composite train roof structure on the basis of analysis results.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.1
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• pp.94-99
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• 2004

The global stiffnesses and vibration characteristics of vehicle structures are mainly influenced by local stiffnesses of the joint structures consisted of complicated thin-walled panels. In this paper, the parametric study for the stiffnesses of the center pillar-roof rail joint of vehicle structure is performed through the linear static analysis. The analysis result shows that the reinforcement panel much affects the joint stiffness of out-plane direction (i.e., z-direction). And also, the flange radius and width of the joint structure much affect the Joint stiffness of out-plane direction. The study shows that vehicle joint stiffnesses can be effectively determined in designing vehicle structure through the parametric study.

• Transactions of the Korean Society of Automotive Engineers
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• v.5 no.1
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• pp.59-68
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• 1997

The modelling techniques of a center pillar-to-roof rail joint for low frequency vibration analysis are examined and some fundamental problems are addressed. To develop a simplified beam-spring model of the joint, the present work is focused on 1) practical shell modelling techniques and 2) joint spring stiffness estimation methods a practical model-updating method to match the calculated natural frequencies to the experimentally determine ones is proposed, particularly focusing on spot welding modelling. In joint spring modelling, the results from the model with one joint spring are compared with those from the model with three coupled springs. Finally, some fundamental problems in beam-spring modelling are addressed.

• Proceedings of the KSR Conference
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• 2011.10a
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• pp.2439-2449
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• 2011

Existing grade crossings between railway and roadway area gradually changed to grade separation systems by the law. In the case of new roadway construction which crosses railways, it shall be grade separation system in principle. With the railway underground crossing method, many practices have been developed which can minimize rail displacements and avoid rail release. With these methods, the effects to the train can be reduced. The underground crossing methods can be identified as open-cut methods and non open-cut methods. The open-cut methods include temporary support methods and special rail construction methods. Also the non open-cut methods includes pipe roof methods, front jacking methods, messer shield methods, NTR methods and JES methods. Among these, the most suitable method is applied considering safety, economy, class of each rail system (train passing frequency and velocity), etc. In the non open-cut methods, the cost and duration shall be increased to keep existing rail system during construction. In the open-cut methods which use plate girders, the rail speed shall be restricted due to the displacement and vibration of the girder. In this study new grade separation methods were developed. With this method, the safety during construction can be increased. This method refines temporary support methods, but pc slab girder with huge stiffness is applied instead of plate girders. With this method, the rail displacement can be reduced and higher safety can be obtained during construction. Also construction cost and duration can be minimized because the temporary work and the overburden soil depth can be reduced.