Chang Hee Suh

Shape Optimization of Multilayer Bellows by Using Sequential Experimental Design

Because of their high flexibility and durability, multilayer bellows are manufactured for use in commercial vehicles, while single-layer bellows are manufactured for use in passenger vehicles. A study based on the finite element method (FEM) and shape optimization for the single-layer bellows has been actively performed; however, until now, a study based on the FEM has rarely been performed for the multilayer bellows with gaps between the layers. This paper presents a finite-element modeling scheme for the multilayer bellows to improve simulation reliability during the evaluation of stress and flexibility. For performing shape optimization for the multilayer bellows, DOE (design of experiment) and the Kriging metamodel followed by the D-optimal method are used.

Optimization of Design Parameters for Lock-Claws of Pneumatic Fitting Using Taguchi Method

The stress concentration of lock-claws, which are one of the important parts for pneumatic fitting for a flexible tube connection, was investigated by finite element simulation. In this study, the generation of the local plastic deformation was predicted when the tube was hooked up to a pneumatic fitting in order to disperse the stress concentration, and design optimization was carried out using the Taguchi method. For the optimization, the outer width, bending angle, and inner radius of the lock-claws are used as main variables. As a result, their respective contribution ratios are revealed as 81.3%, 10.9%, and 1.5%. The ratio of the total stress distribution was improved by 4% compared with the initial design of the lock-claws.

The Effects of Process Parameters of Multi-Stage Forming on Springback for a U-Channel made of Ultra-High-Strength Steel

Ultra-high-strength steels (UHSSs) are widely used for lightweight automobile parts, and the control of springback is very important in sheet-metal forming. The object of this study is to verify the effects of multi-stage forming process parameters for U-channel-type automobile parts made of UHSS. Finite element analysis is carried out to predict the formability and springback. The main parameters considered for the multi-stage forming process are the die angle, die radius, and punch-forming direction. It is shown that multi-stage forming is very effective for reducing springback, and that a small punch-forming angle and die radius reduce springback, whereas the die angle does not have a large effect.

Low-Cycle Fatigue in Quenched Boron Steel Sheet Due to Hot Stamping

Boron steel sheet is suitable for fabricating automobile parts because it is very strong and has low weight. Recently, many car makers are investigating the feasibility of fabricating the chassis part of automobiles using boron steel. In order to use boron steel sheets to fabricate the chassis part of automobiles, much better material property of low cycle fatigue life as well as high formability during hot stamping is required. Therefore, the low-cycle fatigue life of hot-stamped quenched boron steel was investigated in this study. The fatigue life observed at low strain amplitude was longer than that of an as-received boron steel sheet. However, the fatigue life reduced at high strain amplitude because of the low ductility and low fracture toughness of martensite, which was produced as a result of hot stamping.

Study on Fatigue Characteristic of Suspension Part Using Hot Forming

Hot forming using boron steel is currently used for manufacturing low-weight automobile body parts, and a high tensile strength of about 1,500 MPa is obtained after hot forming. However, a high fatigue life is a more important factor than high strength when it is used for automobile suspension parts. A tubular torsion beam axle (TTBA) is one of these suspension parts, and this research deals with the fatigue characteristic of TTBA using hot forming. The low cyclic fatigue life of boron steel is investigated according to the cooling method. In addition, a structural and fatigue analysis of TTBA is performed to predict the fatigue life. The stress concentration that occurs in the tubular torsion beam is found, and the longest fatigue life occurs when rapid cooling is utilized in the TTBA fabrication.

Effect of cooling rate during hot stamping on low cyclic fatigue of boron steel sheet

Boron steel is widely used throughout the automobile industry due to its high tensile strength and hardenability. When boron steel is used for body parts, only high strength is required for crashworthiness. However, when boron steel is used for chassis parts, a high fatigue life is needed. The microstructure of boron steel is mainly affected by the cooling rate during hot stamping. Therefore, this study investigated the low cyclic fatigue life according to the cooling rate. The fatigue life increased at a low strain amplitude when the cooling rate was fast. However, at a high strain amplitude, the fatigue life decreased, due to the low ductility and fracture toughness of the martensite formed by rapid cooling. Martensite formed by a fast cooling rate shows excellent fatigue life at a low total strain amplitude; however, a multiphase microstructure formed by a slow cooling rate is recommended if the parts experience high and low total strain amplitudes alternately. In addition, the cooling rate has little effect on the distribution of solute boron and boron precipitations, so it is expected that boron rarely affects low cyclic fatigue.

Hybrid quenching method of hot stamping for automotive tubular beams

Recently, tubular-type coupled torsion beam axle, which is a component of the automotive rear suspension systems, has been developed by using ultra-high strength steel. It is manufactured by hot stamping process to enhance the strength and reduce springback. The hot stamping process is classified as a direct method and an indirect method according to forming sequence and quenching method, so-called die quenching or water quenching. Each of these methods has limitations in the aspect of dimensional accuracy and strength. Hybrid quenching is a new quenching method which sprays water to the tube directly in addition to die quenching. In this study, direct hot stamping with hybrid quenching was applied to produce an automotive tubular coupled torsion beam axle of ultra-high strength steel. This study proposes a simulation method of hybrid quenching for tubular beam and the hybrid quenching method was evaluated experimentally. Finally, the proposed hybrid quenching method has been found very effective in reducing the cooling time and thermal deformation.