• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 추계학술대회 논문집
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• pp.66-70
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• 2001

The purpose of this paper is to investigate the characteristics of springback for the U-bending of steel sheets for automotive body panels. This study presents the experimental and analytical approach for the two kind of steel sheets, namely SCP1 and TRIP(Transformation-induced plasticity), the newly developed high strength steel. The adopted thicknesses are 0.8, 1.2 and 1.6 mm for SCP1, and 1.0 mm for TRIP. The punch profile radii are designed in 3, 6, 9, 12, and 15 mm. As results, the springgo aspect could be observed experimently in the small punch profile radius. The degree of springback for TRIP sheets was more than the SCP1 sheets.

• Journal of Welding and Joining
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• 제20권3호
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• pp.122-128
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• 2002

The laser welding in the automotive industries has been used widely for the butt joint of blank sheets rather than the lap joint of automotive body panels. But as a substitute far the spot welding of automotive body panels, the so called three dimensional laser welding will be important far the body panel engineers. Specially the laser welding of body panels with a smooth weld line is applied increasingly, for example, to the side panels. So far, some criteria of the laser weld quality was suggested by in-house regulations or national standards from experiences and/or rule of thumbs. In the manufacturing places, a go or no-go criterion is adopted because of the simplicity or a lack of rational criteria. It is true specially for the selection of the process parameters, which gives the basic causes for the good quality of laser welds. In this study, the effects of joint combination, gap and welding speed on the lap joint $CO_2$ laser welding of two mild steel sheets with different thicknesses are obtained through a $2{\times}3{\times}7$ factorial experiment. The results of the weld quality are statistically analysed using analysis of variance (ANOVA) and compared between two characteristic zones, which are separated by the type of sectional shapes and the level of input energy per volume. The thickness combinations are 0.8mm/1.2mm, 1.2mm/0.8mm of mild steel sheets. The welding speed covers from the deep penetration to the partial penetration. The gap size has three levels of no-gap, 0.16m, and 0.26mm. The bead width, penetration depth and input energy per volume are measured and used as the weld quality criteria.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2004년도 추계학술대회 논문집
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• pp.1483-1486
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• 2004

Purpose of this paper is to accummulate database of automotive steel sheet from mild steel to high strength steel in cold rolled steel sheets. Physical properties, mainly mechanical properties, of steel sheet are tested and all data are arranged to one sheet. Methods of test are composed of FLD, tensile strength test, chemical composition, surface roughness and product conditions. Finally this database will be helpful to automotive body designers and die designers to design automotive body parts and tools in a material point of view.

• 한국자동차공학회논문집
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• 제2권1호
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• pp.73-83
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• 1994

Press formabilities of aluminum sheets for automobile body were investigated. Plane strain stretching test (called RIST-PSST), cupping test and U bending test were performed to assess the press formability of aluminum sheets respectively. The results showed that aluminum sheets are generally inferior to cold-rolled steel sheet of deep drawing quality (CSP3N) in press formability. The limiting punch height (LPH) and limiting plane strain (FLCo) of aluminum sheets are 50%-70% level compared to that of CSP3N. Moreover, the limiting drawing ratios(LDR) of aluminum sheets are ranged between 1.95 and 2.1. The poor press formability of aluminum sheets is responsible for low values of total elongation and plastic anisotropy parameter in tensile characteristic. The shape fixability of aluminum sheets evaluated in U bending test is very poor due to its low elastic modulus compared to CSP3N.

• International Journal of Automotive Technology
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• 제6권3호
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• pp.259-268
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• 2005

In order to analyze the sheet drawability, the measurement of the plastic strain ratio was carried out for the 5182 aluminum alloy sheets in which were cold rolled without lubrication and subsequent recrystallization annealing. The average plastic strain ratio of the 5182 aluminum sheets was 1.50. It was considered that the higher plastic strain ratio was resulted from the ND//<111> component evolved during rolling and maintained during annealing. The AA5182/polypropylene/AA5182 (AA/PP/AA) sandwich sheets of the 5182 aluminum alloy skin sheet and the polypropylene core sheet with high formability have been developed for application for automotive body panels in future light weight vehicles with significant weight reduction. The AA/PP/AA sandwich sheets were fabricated by the adhesion of the core sheet and the upper and lower skin sheets. The AA/PP/AA sandwich sheet had high plastic strain ratio (1.58), however, the planar anisotropy of the sandwich sheet was little changed after fabrication. The optimum combination of directionality of the upper and lower skin sheets having high plastic strain ratio and low planar anisotropy was calculated theoretically and an advanced process for producing the sandwich sheets with high plastic strain ratio was proposed. The developed sandwich sheets have a high average plastic strain ratio of 1.55 and a low planar anisotropy of 0.17, which was improved more by 3.2 times than that of 5182 aluminum single sheet.

• International Journal of Automotive Technology
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• 제7권4호
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• pp.485-492
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• 2006

The AA5182/polypropylene/AA5182(AA/PP/AA) sandwich sheets have been developed for application to automotive body panels in future lightweight vehicles with significant weight reduction. It has been reported that the AA5182 aluminum sheet shows $L\"{u}ders$ band because of dissolved Mg atoms that cause fabrication process problem, especially surface roughness. The examination of serration behavior has been made after the tensile deformation of the AA/PP/AA sandwich sheets as well as that of the AA5182 aluminum skins at room and elevated temperatures. All sandwich sheets and the AA5182 aluminum skin showed serration behavior on their flow curves. However, the magnitude of serration was significantly diminished in the sandwich sheet with high volume fraction of the polypropylene core. According to the results of the analysis of the surface roughness following the tensile test, $L\"{u}ders$ band depth of the sandwich sheet evidently showed lower than that of the AA5182 aluminum skin. The strain rate sensitivity, m-value, of the AA5182 aluminum skin was -0.006. By attaching these skins to the polypropylene core, which has relatively large positive value of 0.050, m-value of the sandwich sheets changed to the positive value. The serration mechanism of the sandwich sheets was quantitatively investigated in the point of the effect on polypropylene thickness variation, that on the strain rate sensitivity and that on the localized stress state.

• 한국자동차공학회논문집
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• 제17권4호
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• pp.48-54
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• 2009

The demand for formable high-strength steel (HSS) sheets has recently increased to reduce the weight of automotive bodies. The 340MPa (Tensile Strength) grade steel sheets are widely used for body inner and outer panels. Especially, super formable 340MPa grade steel sheets with high r-value have an excellent deep drawability compared with the other 340MPa grade steel sheets. It is very available for a part such as rear floor, center floor and dash panels used conventional mild steels up to now. We developed a super formable HSS by optimization of chemical composition, texture control and heat treatment control. It has good mechanical properties with excellent formability (tensile strength: 343MPa, elongation: 41.1% and $\bar{r}=2.1$).

• Corrosion Science and Technology
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• 제2권5호
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• pp.247-251
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• 2003

The corrosion forms of automotive body panels are various. One of the representations is a corrosion pitting and its propagation on the lapped portion by galvanic corrosion. But it has been difficult in correlation analysis about the corrosion propagation rate and mechanism of pitting and the actual automotive body in field. This present study interprets experimentally the rust pitting occurrence mechanism on the lapped panels through experimental methods. And field car investigation was executed for correlation analysis with experimental results. This paper compares corrosion propagation rate by pitting on hot-dip galvannealed steel sheets with corrosion forms in the automotive field condition. The research fundamentals which make it possible to predict the pitting occurrence and propagation on the lapped panels in the actual vehicles are given.

• 오토저널
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• 제14권1호
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• pp.3-12
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• 1992

본 고에서는 경량화 소재로서 최근 주목을 받고 있는 알루미늄 판재를 대상으로 알루미늄 판재의 기본 물성과 스탬핑 성형특성에 대하여 검토하고 대량, 고속 생산체계의 확립을 위해 스탬핑 성형기술면에서 해결하여야 할 과제에 대하여 논하고자 한다.

• 소성∙가공
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• 제20권2호
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• pp.160-166
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• 2011

Weight reduction while maintaining functional requirements is one of the major goals in the automotive industry. The use of lightweight magnesium alloys offers great potential for reducing weight because of the low density of these alloys. However, the formability and the surface quality of the final magnesium alloy product for auto-body structures are not acceptable without a careful optimization of the design parameters. In order to overcome some of the main formability limitations in the stamping of magnesium alloys, a new approach, the so-called "hybrid technology", has been recently proposed for body-in-white structural components. Within this approach, necessary level of mechanical joining can be obtained through the use of lightweight material-steel adhesion promoters. This paper presents the development process of an automotive hybrid hood assembly using magnesium alloy sheets. In the first set of material pairs, the selected materials are magnesium alloy AZ31B alloy and steel(SGCEN) as inner and outer panels, respectively. In order to optimize the design of the inner panel, the stamping process was analyzed with the finite element method (FEM). Laser welding by CW Nd:YAG were used to join the magnesium alloy sheets. Based on the simulation results and mechanical test results of the joints, the determination of die design variables and their influence on formability were discussed. Furthermore, a prototype based on the proposed design was manufactured and the static stiffness test was carried out. The results demonstrate the feasibility of the proposed hybrid hood with a weight reduction of 25.7%.