• 한국기계기술학회지
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• 제13권2호
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• pp.155-163
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• 2011

The flat type automotive cross members with high strength steel have advantages in light weight and fewer parts compared to the hump type cross members. But the complex part shape of the flat type cross member and the poor formability of high strength steel make it difficult to form the parts without forming defects, such as splits and wrinkles. The purpose of this study is to develop the flat type automotive cross member with high strength steel. For that purpose, drawing processes are evaluated using PAM-$STAMP^{TM}$ and proper draw die and blank designs are proposed. Using the proposed die and blank design, the flat type upper and lower cross member could be formed successfully without forming defects.

• 소성∙가공
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• 제17권7호
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• pp.481-485
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• 2008

The subframe type rear suspension consisting of a side member and a front/rear cross member is widely used in a medium car and full car. In the small car case, the beam of tubular type without independent suspension system is used to reduce manufacturing cost. In this study, a subframe type rear suspension by hydroforming has been developed. In designing suspension, a driving stability and durability should be considered as an important factor for the performance improvement, respectively. Thus, we focus on increasing the stiffness of suspension and decreasing the maximum stress affecting a durability cycle life. Several optimization design techniques such as shape, size, and topology optimization are implemented to meet these requirements. The shapes of rear suspension obtained from optimization are formed by using hydroforming process. Through commercial software based on the finite element, the superiority of this design method is demonstrated.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.205-208
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• 2008

Generally, there are several types in rear suspension. The rear suspension of subframe type consisting of side member and front/rear cross member is widely used in a medium car and full car. In the small car case, the beam of tubular type without independent suspension system is used to reduce manufacturing cost. The optimized rear suspension of subframe type using hydroforming method has been developed in this study. In designing suspension, the driving stability and durability performance should be considered as an important factor. The stability is related to dynamic frequency and durability is connected with stress analysis of structure. We focus on increasing the stiffness of suspension and decreasing the maximum stress relating to durability cycle life. For making use of the merits of hydroforming which is possible to make the bead, tube expansion, and feeding in desiring position, several optimization design techniques such as shape, size, and topology optimization are proposed. This optimization scheme based on the sensitivity can provide distinguished performance improvement in using hydroforming. Through commercial software based on the finite element, the superiority of this design method is demonstrated.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.353-356
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• 2008

Tool design is carried out for a press forming of a cross member in the rear suspension assembly based on the result of the finite element analysis. The analysis simulates the two-stage stamping process with the initial design and it fully reveals the unfavorable mechanism which develops inferiorities during forming. In this paper, a new design guideline is proposed to modify the process and tool shapes for a single-stage forming process. With the improved tool design, this study fabricates prototypes that satisfy the durability requirement.

• 한국전산구조공학회논문집
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• 제21권6호
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• pp.555-561
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• 2008

본 논문에서는 한국기계연구원에서 개발된 자동차 서스펜션을 대상으로 한 협업설계 지원 엔지니어링 프레임워크 개발에 관하여 기술한다. 개발된 엔지니어링 프레임워크는 각 분야별 전문가 지식에 기초한 엔지니어링 task agent를 포함한 다양한 복수 계층의 소프트웨어 에이전트로 구성된다. 본 프레임워크는 폭 넓은 국내 중소제조기업 적용 확산을 목적으로 JADE(Java Agent Development Framework)와 같은 공개 소스 프로그램 기반으로 개발하였으며, 프레임워크의 확장성을 유지하기 위하여 관련 H/W 및 응용 S/W의 독립성을 가능한 한 유지하도록 노력하였다. 개발된 프레임워크는 제품개발과 정에 있어 지역적으로 분산된 사용자 및 엔지니어링 자원 등을 효과적으로 활용할 수 있는 통합된 협업 설계환경을 제공한다. RR/FR lower arm 및 RR cross member와 같은 몇 개의 실제 자동차 서스펜션 모듈의 설계엔지니어링 문제에의 적용을 통하여 본 시스템의 적용성과 효율성을 확인하였다.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2008년도 추계학술대회A
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• pp.1320-1325
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• 2008

In the manufacture of automobile suspension modules at a company as parts supplier, the design process includes the detail design and the design modification via structural and fatigue durability analyses considering PoF(physics of failure) of their weldments that are repeated more than four times sequentially. The approval of the design and the release of final drawings follows. For the suspension modules, e.g. control arms and cross member, the man-hours per worker required in the process outlined above can reach as high as 1,414hours. Application of the developed integrated design system can reduce the man-hours of 1,004. In comparison with the conventional design process, this integrated design system reduces the required time by about 40%. If expense is taken into account, a savings of approximately $192,000 is estimated, assuming the design process accounts for 1.5% of total sales for the parts supplier