• Journal of Welding and Joining
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• 제33권4호
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• pp.50-56
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• 2015

In general, discontinuity of metallurgical and structural points of weld zone could decline the fatigue strength. For the lightweight trend, the AHSS application in automotive chassis is in-progress. However, there are few research reports on AHSS welds fatigue strength in especially automotive chassis parts. Therefore, in this study, we evaluated the effects of the factors affecting the AHSS welding fatigue strength. As the result, the stress concentration of weld bead is the most important factor for welding fatigue strength. For the enhancement of welding fatigue strength, we focused on reducing the stress concentration of the welding beads. So, we applied and proved the plasma welding process and GTAW (Gas Tungsten Arc Welding) dressing method. It was verified by uniaxial fatigue specimen, fatigue performance increased from 40 to 60% by applying TIG dressing method compared to the conventional GMAW (Gas Metal Arc Welding). These results could be recommended the enhancement of fatigue performance of AHSS.

• 한국자동차공학회논문집
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• 제16권6호
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• pp.58-64
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• 2008

An aluminum radius rod using rheo-forging method has been developed for heavy commercial vehicles to decrease vehicle unsprung weight. To design the shape of the rod, structural simulations are performed using two load cases. To evaluate durability performance of the rods, a test system which has simultaneous 3 axes actuating system is developed. And 3 axes durability test conditions are established based on vehicle field tests. Using the test systems and the conditions, the durability test is carried out and the rods have passed the test conditions of 700,000 cycles. The weight of a developed aluminum radius rod is 4.2kg and it was drastically reduced by 48.8 percent in comparison with the weight of a steel radius rod.

• Journal of Welding and Joining
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• 제23권4호
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• pp.59-65
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• 2005

The resistance spot welding is one of the most commonly used welding process for joining the sheet metal in automotive manufacturing process due to higher deposition rates and higher economy achieved. Control variables in the resistance spot welding for achieving high quality are welding current, welding force and welding time. Generally at the manufacturing scene, welding current Vs welding time lobe diagram is used to estimate weldability because controlling welding force is not practical due to economical reasons. However new automotive steel plates have been developed to make lightweight automobiles and to improve resistance against rusting. Also the weldability of these steel plates are worst than the existing steel plates because of changing bare metal and surface plating effect. In consequence of above mentioned reasons, it is necessary to use welding force to present the lobe diagram. In this study, we obtained the welding force Vs welding current lobe diagram for commonly used GA steel plate and found that the second order repression model of tensile shear strength was useful in reducing the number of experiments, and the indentation, and thickness change during welding were used as a response to estimate quantitatively expulsion.

• 한국자동차공학회논문집
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• 제23권3호
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• pp.279-286
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• 2015

To achieve lightweight design, research & development of various lightweighting technologies such as hydroforming are underway worldwide. In the case of hydroforming, application of ultra high strength steel is essential for weight reduction of the car. However, considering common high-strength carbon steel, it is not suitable to the actual hydroformed parts since the lack of formability. DP steel offers an outstanding combination of strength and formability as a result of their microstructure. DP steel has high strength and good formability but it's difficult to secure stable quality of welding section because of softening of weld section and chemical composition. Therefore, most of companies use LASER welding when making high strength tube. Electric resistance welding is excellent production method for steel tube manufacturing considering the productivity. Optimum electric resistance welding technology is needed to be developed for application of high strength hydroformed parts using DP steel. This study is comprehensive research & development from electric resistance welding to actual formabililty evaluation.

• Composites Research
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• 제32권5호
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• pp.243-248
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• 2019

As demand of light weight in the automotive industry has increased, the cowl cross member has been investigated using various methods to change the material. Conventionally, a cowl cross member has been made of steel and aluminum, but recently researchers tested multi-material such as aluminum and plastic. We studied a new model of the cowl cross member made of composite and non ferrous materials. For products with a high degree of freedom in design, generally, the method of topology optimization is advantageous and for the partial bracket part of the cowl cross member had a degree of freedom in the design, a topology optimization is appropriate. Considering the characteristics of the cowl cross members, we need research to minimize the weight while having the performance of noise, vibration and harshness(NVH). Taking the mounting status of the product into consideration, we used an assembly model to optimize the cowl cross member. But this method took too much time so we considered simple cowl cross member assemble conditions using the direct matrix input method(DMI) with the Craig-Bampton Nodal Method. This method is capable of considering the status of the assembly without assembling the model, which reduced the solving time and increased the accuracy comparison with a cowl cross member without DMI.

• 전기전자학회논문지
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• 제28권3호
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• pp.412-418
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• 2024

본 논문은 RANSAC(Random Sample Consensus) 알고리즘을 활용하여 차량용 CAN 통신에서 발생하는 해킹 공격을 효과적으로 탐지하는 방법을 제안한다. 기존에 제안된 딥러닝 기반 탐지 기법은 차량과 같이 리소스가 제한된 환경에는 적용하기 어렵다는 한계가 있다. 본 논문에서는 RANSAC 알고리즘의 경량성과 효율성을 활용하여 차량용 CAN 통신에서의 공격 탐지 성능을 향상시켰다. RANSAC 알고리즘은 적은 연산 자원으로도 효과적인 탐지를 수행할 수 있어서 차량에 탑재 가능한 실용적인 해킹 탐지 솔루션을 제공할 수 있다.

• 한국정밀공학회지
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• 제17권4호
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• pp.7-21
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• 2000

This paper describes an overview of the thixoforming and thixomolding processes. Semi-solid metalworking (SSM), which is called the thixoforming process of aluminium materials, incorporates the elements of both casting and for the manufacture of near net shape parts. The SSM has some advantages such as net shape or near net shape manufacturing, the ability to form thin walls, excellent surface finish, tight tolerance, and excellent dimensional precision. The thixomolding process of Mg alloy (AZ9l) is a combination of two technologies both conventional die casting and plastic injection molding. The feed material used is a machined chip with a geometry of approximately 1 mm square and a length of 2~3 mm. The semi-solid forming (SSF) of high quality aluminium and magnesium parts will be established in the automotive and electronic industry, in the future. The hybrid method of casting/forging has been caused attention. This process uses a preformed material made by casting instead of the wrought material and finishes it by a single forging process. This process is expected to lower costs without sacrificing the mechanical and finishes it by a single forging process. The process is expected to lower costs without sacrificing the mechanical properties. The authors, intending that the casting/forging process contributes to a reduction in production cost of aluminum automotive parts in Korea, describes the feature of the casting/forging process, aluminum alloys suitable for the cast preform, microstructure and mechanical properties of the cast preform, application examples of cast/forging, and further study.

• 산업경영시스템학회지
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• 제40권1호
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• pp.35-40
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• 2017

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• 산업경영시스템학회지
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• 제42권1호
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• pp.1-7
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• 2019

In the modern industrial period, the introduction of mass production was most important progress in civilization. Die-casting process is one of main methods for mass production in the modern industry. The aluminum die-casting in the mold filling process is very complicated where flow momentum is the high velocity of the liquid metal. Actually, it is almost impossible in complex parts exactly to figure the mold filling performance out with the experimental knowledge. The aluminum die-castings are important processes in the automotive industry to produce the lightweight automobile bodies. Due to this condition, the simulation is going to be more critical role in the design procedure. Simulation can give the best solution of a casting system and also enhance the casting quality. The cost and time savings of the casting layout design are the most advantage of Computer Aided Engineering (CAE). Generally, the relations of casting conditions such as injection system, gate system, and cooling system should be considered when designing the casting layout. Due to the various relative matters of the above conditions, product defects such as defect extent and location are significantly difference. In this research by using the simulation software (AnyCasting), CAE simulation was conducted with three layout designs to find out the best alternative for the casting layout design of an automotive Oil Pan_BJ3E. In order to apply the simulation results into the production die-casting mold, they were analyzed and compared carefully. Internal porosities which are caused by air entrapments during the filling process were predicted and also the results of three models were compared with the modifications of the gate system and overflows. Internal porosities which are occurred during the solidification process are predicted with the solidification analysis. And also the results of the modified gate system are compared.

• Design & Manufacturing
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• 제16권4호
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• pp.24-33
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• 2022

Fiber-reinforced plastics(FRPs) have excellent specific stiffness and strength, so they are usually used as automotive parts that require high rigidity and lightweight instead of metal. However, it is difficult to predict the mechanical properties of injection molded parts due to the fiber orientation and breakage of FRPs. In this paper, the fiber orientation characteristics and mechanical properties of injection molded specimens were evaluated in order to fabricate automotive transmission side covers with FRPs and design a rib structure for improvement of their rigidity. The test molds were designed and manufactured to confirm the fiber orientation characteristics of each position of the injection molded standard plate-shaped specimens, and the tensile properties of the specimens were evaluated according to the injection molding conditions and directions of specimens. A gusset-rib structure was designed to improve the additional structural rigidity of the target products, and a proper rib structure was selected through the flexural tests of the rib-structured specimens. Based on the evaluation of fiber orientation and mechanical characteristics, the optimization analyses of gate location were performed to minimize the warpage of target products. Also, the deformation analyses against the internal pressure of target product were performed to confirm the rigidity improvement by gusset-rib structure. As a result, it could be confirmed that the deformation was reduced by 27~37% compared to the previous model, when the gusset-rib structure was applied to the joining part of the target products.