DOI QR코드

DOI QR Code

Development of Al Bumper Back Beam by Using Curvature Extrusion Process

곡률압출공정을 이용한 알루미늄 Bumper Back Beam 개발

  • 이상곤 (부산대-IFAM 국제공동연구소) ;
  • 조영준 (삼성중공업 거제조선소 의장설계 1 팀) ;
  • 김병민 (부산대학교 기계공학부) ;
  • 박상우 ((주)동양강철 기술연구소) ;
  • 오개희 ((주)동양강철 기술연구소)
  • Published : 2009.05.01

Abstract

Curvature extrusion process has several advantages in comparison to the conventional extrusion and bending process. In the curvature extrusion, the extruded part is directly bent during extrusion. Therefore, it does not need additional bending process after extrusion. In the curvature extrusion process, it is possible to produce curved extruded products that have a constant or various curvatures. It is essential that we predict the curvatures of the extruded product to meet the required curvatures. This paper proposed a theoretical model that can predict the curvature of extruded product produced by the curvature extrusion process. Using the proposed model the movement of guide tool that causes the bending of extruded product was controlled to produce the required curved automotive Al bumper back beam. The effectiveness of the proposed prediction model and the movement of guide tool were verified by the FE analysis and curved extrusion experiment.

Keywords

Curvature Extrusion;Predicting Curvature;Porthole Extrusion;FE-Analysis;Curvature Extrusion Experiment

References

  1. Lange, K., 1985, Handbook of Metal Forming, R. R. Donnelley & Sons Company
  2. Kleiner, K., Chatti, S. and Klaus, A., 2006, 'Metal Forming Techniques for Lightweight Construction,' Journal of Materials Processing Technology, Vol. 177, pp. 2-7 https://doi.org/10.1016/j.jmatprotec.2006.04.085
  3. Clausen, A. H., Hopperstad, O. S and Langseth, M., 2000, 'Stretch Bending of Aluminum Extrusion for Car Bumpers,' Journal of Materials Processing Technology, Vol. 102, pp. 241-248 https://doi.org/10.1016/S0924-0136(99)00487-2
  4. Peter, G., Herber, B., David, K. H., Anjali, K. M. D. S., 2005, 'Free-Bending Technique in the Hydroforming Process Chain,' Journal of Materials Processing Technology, Vol. 46, pp. 1238-1242 https://doi.org/10.1016/j.jmatprotec.2005.05.052
  5. Muller, B. K., 2003, 'Investigation of Material Flow During the Concurrent Bending and Extrusion Process of Al-Profiles,' Proceeding of ESAFORM Congress, April
  6. Murata, M. and Mochizuki, T., 1999, 'Noncontrasted Bending of Square Tube Using MOS Bending Method,' Proceeding of Japanese Spring Conference for the Technology of Plasticity, May
  7. Jo, H. H., Lee, S. K., Lee, S. B. and Kim, B. M., 2002, 'Prediction of Welding Pressure in the Non-Steady State Porthole Die Extrusion of Al7003 Tubes,' International Journal of Machine Tools & Manufacture, Vol. 22, pp. 753-759
  8. Jo, H. H., Lee, S. K., Jung, C. S. and Kim, B. M., 2006, 'A Non-Steady State FE Analysis of Al Tubes Hot Extrusion by a Porthole Die,' Journal of Materials Processing Technology, Vol. 173, pp. 223-231 https://doi.org/10.1016/j.jmatprotec.2005.03.039
  9. SFTC, 2004, DEFORM-3D, Ver. 5.0
  10. Muller, B. K., 2006, 'Bending of Extruded Profiles during Extrusion Process,' International Journal of Machine Tools & Manufacture, Vol. 46, pp. 1238-1242 https://doi.org/10.1016/j.ijmachtools.2006.01.036
  11. Jo, Y. J., Lee, S. K., Kim, B. M., Oh, K. H. and Park, S. W., 2008, 'Process Development of Variable Curvature Extrusion for Automotive Aluminum Bumper,' Trans, of the KSME (A), Vol. 32, No. 5, pp. 327-332 https://doi.org/10.3795/KSME-A.2008.32.4.327