• Transactions of Materials Processing
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• v.7 no.6
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• pp.603-609
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• 1998

An aluminium sandwich sheet is the material fabricated by adhering two aluminum panels to one plastic core. When it has the same bending stiffness as an steel panel it is 65% lighter than steel panel and 30% lighter than aluminum panel. Therefore it is notified exclusively as good substitutive materials for steel body to improve fuel efficiency. An aluminium sandwich sheet, however, has a problem of the lower formability than steel in automotive application. In this paper we intend to develop application technologies of an aluminum sandwich sheet for auto body panels from selecting composed materials of aluminium sandwich sheets to fabricating prototype. We selected aluminium sandwich panels fabricated by Hoogovens company. Through formability tests we have designed the hood part on auto body panels and fabricated a mould and a prototype.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.131-139
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• 1998

An aluminium sandwich sheet is the material fabricated by adhering two aluminum panels to one plastic core. If it has the same bending stiffness as an steel panel, it is 65% lighter than steel panel and 30% lighter than aluminum panel. Therefore it is marked exclusively as god substitutive materials of steel body for improving fuel efficiency. But an aluminium sandwich sheet has problem of the lower formability than steel for automotive application. In this paper we intend to develop application technologies of an aluminum sandwich sheet for auto body panels from the selecting composed materials of aluminium sandwich sheets to fabricating prototype. We selected aluminium sandwich panels fabricated by Hoogovens company. Through formability tests we have finished the design and fabricated a mould and a prototype.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.385-388
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• 2004

The influence of material properties and process parameters on the strain distribution of stamping parts was studied by finite element method. For the parametric study, the investigation of variation of material properties was carried out with tensile test for a dozens of different steel sheets. The friction test for each surface and lubricants conditions are also carried out because the frictional characteristic is important parameter fur sheet metal forming. The geometry of stamping parts was measured by 3D scanner to build the tool model fer the FE analysis. As a result of analysis the major process parameter fer each automotive parts was investigated.

• Journal of the korean Society of Automotive Engineers
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• v.18 no.5
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• pp.24-37
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• 1996

자동차용 열연강판은 그 용도에 따라 매우 다양한 제품특성이 요구되고 있다. 즉 고강도 및 고강성, 우수한 피로특성, 용접성 및 내식성 등이 요구되고 있다. 이중에서도 고강도화는 향후 자동차의 경량화와 더불어 안전성을 동시에 확보하기 위해 매우 필요한 기술이다. 고강도화에 가장 많은 노력이 이루어졌던 wheel용 강재의 경우, 기존에는 60kg급 강재가 주종을 이루었으나, 일본등에서는 80kg급 강재의 시험생산 및 실차 test가 진행되는 등 소재공급사와 자동차제조사와의 공동노력에 의해 많은 기술개발이 이루어져 왔다. 더우기 96년 6월 일본철강연맹 규격에는 자동차용 열간압연 강판으로 80kg급 강재가 등록이 됨으로서 향후 고강도강의 소요가 크게 증가될 전망이다. 또한 근래 상용화가 활발하게 진행되고 있는 열연 TRIP강의 경우 기존의 개념을 넘어서는 고강도 및 고연성, 우수한 가공선과 더불어 우수한 피로특성을 보이고 있어 향후 동 소재의 사용확대가 크게 기대되고 있다. 그러나 이러한 좋은 철강소재의 개발과 이의 적용은 강재제조기술과 더불어 이의 적정 가공기술 그리고 독자적인 설계기술등이 연계되어야만 비로소 이루어질 수 있다. 이를 위해 소재공급사와 자동차제조사간에 지속적인 기술개발을 위한 공동노력이 이루어져야 되리라 생각된다.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.73-82
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• 2016

Recently, automobile industries have been developing many structural automotive parts made of thin, high-strength steel strips to produce safer and more environmentally friendly cars. The roll forming process has been considered one of the most efficient processes in manufacturing high-strength steel parts because it is a high-speed process that forms sheets in increments. However, most automotive parts vary longitudinally in their cross-sections. Therefore, it is difficult to apply the roll forming process to automotive parts made of high-strength steel. A variable section roll forming process has been proposed in recent studies. The rotational axes of the forming rolls are fixed, and the forming rolls have three-dimensional shape. As such, the cross-section of the part varies linearly along its length, and the angle between the bend line and longitudinal axis is less than 1 degree. Thus, the rate of cross-sectional variation along the length is relatively small. In this study, the rate of cross-sectional change along the length of a forming roll has been increased. Moreover, the angle between the bend line and longitudinal axis has been increased up to 15 degrees. The variable sections of the forming rolls have been designed for high strength steel parts with a symmetric u-type cross-section that varies linearly and symmetrically along the longitudinal axis.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.24-29
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• 2021

Recently, owing to the high demand for eco-friendly cars in the automotive industry, noise and vibrations have become major challenges. The use of laminated damping steel is increasing in response to these demands. Laminated damping steel is primarily used in sound insulation plates. The vibration energy is converted into thermal energy due to the viscoelastic resin being located between two steel sheets and being able to damp the vibrations when an external force, such as, noise or vibration is applied to the steel plate. Laminated damping steel is chiefly applied to dash panels in automotive body parts, and because of its structure, junction technology for bonding with other components is necessary. However, there has not been sufficient research conducted on junctions. In this study, regardless of the electrode shape, in the range of 4.0 ~ 8.0 kA welding current, the same welding force and welding time were applied which were 2.8 kN and 200 m/s (12 cycles) and the tensile shear load and nugget size were analyzed after the resistance spot welding between different materials of laminated damping steel with a thickness of 1.035 mm. The results show that in the range of 5 ~ 8 kA welding current, 1.035 mm laminated damping steel meets the MS181-15 standard, which is the technical standard of Hyundai-Kia Motors.

• Transactions of Materials Processing
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• v.14 no.9 s.81
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• pp.764-771
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• 2005

This study is related with the development of CNC spinning machine and the axisymmetric conventional spinning such as drum type and conical type steel shells. The CNC spinning machine is constructed with heavy duty frame and the hydraulic servo system is applied in order to give the exactness of motion control. The experiment has been carried out considering feeding velocity, mandrel shape, and the corner radius of mandrel and forming rollers. As a result of experiment, the limiting spinning ratio and thickness strain distribution are obtained and it can be seen that the spinnability is dominant to the feeding velocity and corner radius of forming roller. This research can contribute to the development of axisymmetric mechanical part which is applicable to automotive and aerospace industry.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.4
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• pp.350-354
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• 2014

Recently, high strength steel (HSS) sheet metal has been widely used to improve lightweight structures in the automotive industry. Because HSS sheets have high strength but low elongation, it is difficult both to make products with complex shapes and to control excessive springback. In order to reduce the springback after forming using HSS, draw beads were introduced in this study. The design variables, including the draw-bead positions and shapes, were optimized using a finite element analysis. A mold for a scanner support, which is part of an A3 printer, was designed using the proposed method and then utilized. The results from a finite element simulation and optimization were compared with the experiment results.

• Journal of Welding and Joining
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• v.28 no.1
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• pp.77-85
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• 2010

Stainless steel sheets are widely used as the structure material for the railroad cars and the commercial vehicles. These kinds structures used stainless steel sheets are commonly fabricated by using the gas welding. Gas welding is very important and useful technology in fabrication of a railroad car and vehicles structure.However fatigue strength of the gas welded joints is considerably lower than parent metal due to stress concentration at the weld, fatigue strength evaluation of gas welded joints are very important to evaluate the reliability and durability of railroad cars and to establish a criterion of long life fatigue design. In this paper, $({\Delta}{\sigma}_a)_R-N_f$ curve were obtained by fatigue tests. Using these results, the accelerated life test(ALT) was conducted. From the experimental results, an acceleration model was derived and acceleration factors are estimated. So it is intended to obtain the useful information for the fatigue lifetime of plug and ring gas welded joints and data analysis by statistic reliability method, to save time and cost, and to develop optimum accelerated life prediction plans.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1317-1321
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• 2007

Aluminized steel sheet that Al coated on low carbon steel has a excellent heat resistance, thermal reflection and corrosion resistance. It has applied to fuel tank, automotive exhaust systems, etc. Laser weldability of the aluminized steel for the full penetration welding will be described in this paper. We focused on the effect of Al coating conditions on weld strength. For these objectives, aluminized steel sheets that has various thickness and coating weight were prepared for laser welding. And then, tensile-shear and hardness test were carried out. At that same time, Al content mixed in weld after laser welding was evaluated and investigated a correlation between the mixed Al and mechanical properties. Besides, as removing partially coating layer, weldability has been investigated according to position of coating layer. As a result of this study, as increasing Al content in weld, tensile-shear strength was decreased. Also it was identified that Al of coating layer caused grain growth.