• 소성∙가공
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• 제31권3호
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• pp.129-135
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• 2022

The purpose of this study was to quantitatively evaluate the influence of hardness of tool materials on wear resistance in the sheet metal forming process. Punches used in the wear test were made of STD-11 and K340 tool material, and the tempering temperature was set to 530℃ and 500℃, respectively, to control the hardness of the tool materials. The punches mimic the shape of stamping tool of automotive body component to reflect its plastic deformation, and are designed to concentrate wear on the curvature region of punches. Progressive die and coil sheet were used to save time, cost, and raw sheet materials. By quantitatively measuring the wear depth of the punches, the wear behavior and mechanism of the punches were investigated, and characteristics of hardness and wear resistance according to tool materials and tempering temperatures were evaluated. Testing results indicate that the punch made of K340 tool steel with higher hardness had better wear resistance than that of STD-11 tool steel, and the hardness and wear resistance of tool steel were significantly impacted by the tempering temperature.

• 한국자동차공학회논문집
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• 제14권1호
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• pp.79-85
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• 2006

CFRP(Carbon Fiber Reinforced Plastics) of the advanced composite materials as structural materials for vehicle, has a wide application in light-weigh structural materials of airplanes, ships and automobiles because of high strength and stiffness, However, there is a design variable to be considered in practical application of the laminate composite materials, these materials are vulnerable to transverse impact. This paper is to study the effects of stacking sequence and curvature on the penetration characteristics of composite laminate shell. They are stacked to $[0_3/90_3]S,\;[90_3/0_3]s\;and\;[0_2/90_3/0]s,\;[90_2/0_3/90]s$ and their interlaminar number two and four. They are manufactured to various curvature radius (R=100, 150, 200mm and $\infty$), When the specimen is subjected to transverse impact by a steel ball, the velocity of the steel ball was measured both before and after impact by determing the time for it to pass two ballistics-screen sensors located a known distance apart. The critical penetration energy of specimen A and B with less interfaces were a little higher than those of C and D. As the curvature increases, the critical penetration energy increases linearly because the resistance to the in-plane deformation as well as bending deformation increases, which need higher critical penetration energy. The specimen A and C have higher critical penetration energy than B and D because of different stacking sequences. We examined crack length through a penetration test. For the specimen A with 2interfaces, the longest circumferential direction crack length were observed on the first interface from the impact point. For the specimen B 4-interface, the longest circumferential direction crack length were observed on the second interface from the impact point.

• Journal of Welding and Joining
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• 제28권5호
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• pp.75-79
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• 2010

The Remote welding system(RWS) using $CO_2$ laser equipment has focusable distance of laser beam longer than 800 mm from workpiece and can deflect the laser beam by the scanner mirrors very rapidly. In the case of normal welding system based on robot, there is a limit to move the shortest path in short time and this causes interference between robot and workpiece. On the other hand, RWS is the optimized equipment to get big merits with advanced sequence of welding and short cycle time. However, there is still a pending task such as the control of plasma in the welding process of thick sheets therefore, it requires high power laser beam because of the absence of assist gas equipment in itself. In this study, high-tensile steel plates were overlap welded with $CO_2$ RWS for the production of car body and the influence of penetration depth according to the existence of assist gas was analyzed. Excellent tensile strength with enough width of molten zone independent to penetration depth was observed under welding condition with 3.6 kW laser power and 2.8 m/min welding speed without assist gas. Finally, the proto-type automotive parts were produced by applying the deduced optimal welding condition.

• 소성∙가공
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• 제19권1호
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• pp.44-49
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• 2010

It has been widely reported that carbide-free bainitic steels or super-bainite TRIP (SB-TRIP) steels for the automotive industry are a new family of steels offering a unique combination of high strength and ductility. Hence, it is important to exactly evaluate the volume fraction of RA and to identify the 3-D morphology of constituent phases, because it plays a crucial role in mechanical properties. Recently, as electron back-scattered diffraction (EBSD) equipped with focused ion beam (FIB) has been developed, 3-D EBSD technique for materials science are used to these steels. Moreover, newly developed atom probe tomography (APT) technique can provide the exact distribution and chemical concentration of alloying elements in a sub-nm scale. The APT analysis results indicate exactly the distribution and composition of alloying elements in the austenite and bainite phases of SB-TRIP steels with the atomic-scale resolution. And thus, no partitioning of aluminum and manganese atoms was showed between the austenite containing $7.73{\pm}0.39$ at% C and the bainitic ferrite associated with $0.22{\pm}0.06$ at% C in SB-TRIP steel.

• 한국기계가공학회지
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• 제14권6호
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• pp.7-13
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• 2015

The production processes were reviewed through the injection analysis of the shift lever as a core component of an auto lever installed in the automatic transmission of cars. The injection analysis was carried out for the shift lever and rod among the components in a shift lever module. The shift lever and rod are designed for injection molding with the insertion of a tube, a pin cable plate, and a steel rod for securing the strength of the product. The charging time, failure of injection molding, weld line, air trap, and deformation were reviewed according to this insert. Analyses on various gate positions were carried out for reviewing the cultivation and deformation of fiber around major components, such as the generation section of manipulation feeling and assembly section, so that optimal gate conditions might be reviewed and reflected in the mold design. Finally, we plan to compare the analysis results with the production of trial products.

• 소성∙가공
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• 제23권8호
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• pp.495-500
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• 2014

Magnesium alloys are currently expected to be widely used for weight reduction of cars and as high efficient materials in the automotive and electronics industries. Although the specific strength of magnesium is excellent, it cannot be easily formed at room temperature due to its HCP structure. However in order to improve the formability of magnesium, it is necessary to investigate its formability in the warm temperature range. In the current study, the aim was to add to the magnesium property database so that the mass production of a magnesium car body can be accomplished. Warm tensile tests were conducted and the forming limit diagram was determined to confirm formability characteristics of magnesium AZ31B alloy sheet. In addition the bending formability and the magnesium damping capacity were evaluated for AZ31B and compared to SPRC440E which is a sheet steel used for car bodies.

• 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.

• 대한기계학회논문집A
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• 제32권11호
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• pp.990-996
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• 2008

Nowadays, the trend to a lightweight design accelerates the use of advanced high strength steel (AHSS) in automotive industry. Springback phenomena is a hot issue in the sheet metal forming, especially bending process using AHSS. Several analytical methods for that have been proposed in recent years. Each of method has their advantages and disadvantages. There are only a few optimal solutions which can minimize the two objectives simultaneously. In this study, an effective method optimized the multi objective value. The method by the design of experiments(DOE) and artificial neural network(ANN) was presented to compensate springback of bending parts. This method was applied to L and V bending process. The effective method could be optimized to multiple object. It was confirmed that the proposed method was more efficient than traditional manual FEA procedure and the trial and error approach for springback compensation.

• Journal of Welding and Joining
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• 제28권1호
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• pp.86-91
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• 2010

In the present study, two-dimensional plane deformation thermo elasto-plastic analysis has been carried out, in order to investigate the thermal and mechanical behaviour (residual stress, plastic strain, magnitude of stress and their distribution and production mechanism) on multi-pass FCA butt weldment of high strength EH36-TMCP ultra thick plate. Moreover, this study can be considered as a basis for analysing the fracture toughness, KIC, and its effect on welding residual stress redistribution with notch on multi-pass FCA butt weldment, in future. The results of welding residual stress obtained from thermo elasto-plastic analysis has been compared and verified with the results measured by XRD.

• Design & Manufacturing
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• 제16권3호
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• pp.28-33
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• 2022

The recent increasing application rate of advanced high-strength steel(AHSS) for automotive parts makes it difficult to ensure the durability of forming tools. Significant load and friction generated during the piercing process of AHSS increase the wear rate and the damage degree to dies. These harsh process conditions also yield product failures, such as dimensional inconsistency of pierced holes and insufficient quality of hole's sheared edge. This study analyzed the effect of punch wear on the sheared surface of pierced parts and the forming load during the piercing process. Wear-shaped punches showed approximately 20% higher piercing load than normal-shaped punches, and the rollover ratio of the sheared surface also increased. It is considered that the dull edge of wear-shaped punches does not penetrate directly into the material but shears after tensioning it in a piercing direction. In addition, wear-shaped punches experienced compressive load even after completing the piercing process during the down-stroke and tensile load during the up-stroke. This load variation is related to the smaller diameter piercing holes produced by wear-shaped punches compared to normal-shaped punches. Thus, we demonstrated the predictability of the wear level of dies through a comparative analysis of the piercing load pattern.