• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.21-24
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• 2007

This paper deals with introduction of testing equipments for the evaluation of dynamic tensile characteristics of auto-body steel sheets and the crashworthiness of auto-body members. The servo-hydraulic high speed material testing machine was developed for tensile tests at the intermediate strain rate to obtain the tensile material properties at the strain rate under 500/sec. The split Hopkinson bar apparatus using the elastic wave was developed for dynamic material characteristics at the high strain rate ranged from 1,000 to 10,000/sec. The servo-hydraulic high speed crash testing machine is the equipment for the evaluation of the collapse load and crashworthiness of auto-body members. High speed carrying truck crashes to specimen with the maximum velocity of 17 m/sec.

• Transactions of the Korean Society of Automotive Engineers
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• v.12 no.1
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• pp.91-98
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• 2004

This paper is concerned with crash analysis for an auto-body member with the forming effect. Auto-body members such as a front frame assembly are fabricated with sheet metal forming processes that induce forming histories such as the plastic work hardening and non-uniform thickness distribution. Numerical simulation is carried out with LS-DYNA3D in order to identify the forming effect on the crashworthiness. The crash analysis of the front frame assembly with the forming effect leads to a different result from that without the forming effect. Crashworthiness such as the load-carrying capacity, the crash mode and the energy absorption are calculated to investigate and identify the forming effect. It is fully demonstrated that the design of auto-body members needs to consider the forming effect for accurate assessment of the load-carrying capacity and the deformation mechanism of the formed members.

• Transactions of the Korean Society of Automotive Engineers
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• v.17 no.2
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• pp.104-111
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• 2009

In this paper, optimization for frontal crashworthiness is carried out for the weight reduction design of an auto-body member with the advanced high strength steels(AHSS) such as 780TRIP and 780DP. The frontal crashworthiness is evaluated in order to optimize thicknesses for the front rail member of the ULSAB-AVC, Thicknesses of the front rail member with AHSS are optimized by comparison of crushing distance, absorbed energy and the deceleration for the auto-body with the response surface methodology. The results demonstrate that the crashworhiness of the front rail member with the optimum thicknesses of the AHSS is similar to analysis results obtained from the ULSAB-AVC project. The results also show that the weight reduction design is performed by substituting the AHSS for conventional structural steels such as 440E in the auto-body members.

• International Journal of Automotive Technology
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• v.4 no.3
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• pp.149-156
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• 2003

This paper is concerned with the energy absorption efficiency of auto-body side structures for the conventional steel and 60TRIP high strength steel. In order to evaluate the energy absorption efficiency, the dynamic crash analysis is carried out with the regulation of US-SINCAP. The analysis adopts the Johnson-Cook model for the dynamic material properties, which have been obtained from dynamic material tests. For the sake of the dynamic material properties, the analysis has been accurately peformed for the crashworthiness assesment. The analysis result provides deformed shapes, amounts of penetration and accelerations at several important points during crash. The result confirms that 60TRIP greatly improves the crashworthiness of the side members without sacrificing the weight and thus can be used for the light-weight design of an auto-body.

• International Journal of Automotive Technology
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• v.1 no.1
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• pp.35-41
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• 2000

The crashworthiness of vehicles with finite element methods depends on the geometry modeling and the material properties. The vehicle body structures are generally composed of various members such as frames, stamped panels and deep-drawn parts from sheet metals. In order to ensure the impact characteristics of auto-body structures, the dynamic behavior of sheet metals must be examined to provide the appropriate constitutive relation. In this paper, high strain-rate tensile tests have been carried out with a tension type split Hopkinson bar apparatus specially designed for sheet metals. Experimental results from both static and dynamic tests with the tension split Hopkinson bar apparatus are interpolated to construct the Johnson-Cook and a modified Johnson-Cook equation as the constitutive relation, that should be applied to simulation of the dynamic behavior of auto-body structures. Simulation of auto-body structures has been carried out with an elasto-plastic finite element method with explicit time integration. The stress integration scheme with the plastic predictor-elastic corrector method is adopted in order to accurately keep track of the stress-strain relation for the rate-dependent model accurately. The crashworthiness of the structure with quasi-static constitutive relation is compared to the one with the rate-dependent constitutive model. Numerical simulation has been carried out for frontal frames and a hood of an automobile. Deformed shapes and the Impact energy absorption of the structure are investigated with the variation of the strain rate.

• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.2
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• pp.164-171
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• 2003

The side impact behavior has been investigated when the high strength steel 60TRIP(Transformation Induced Plasticity) is replaced for the conventional low-carbon steel for weight reduction of an auto-body. The side impact analysis was carried out as specified in US-SINCAP with the center pillar and the side sill of the conventional steel or 60TRIP. For accurate impact analyses, the dynamic material properties are adopted with the Johnson-Cook model. The analysis results demonstrate that the penetration of the side members is remarkably reduced when 60TRIP is employed for the center pillar and the side sill replacing the conventional steel. The crashworthiness in the side impact is considerably improved with less penetration of the side members and less acceleration of the opposite floor.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.1
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• pp.171-176
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• 2007

An important challenging issue in the automotive industry is the light-weight, safe design and enhancement of crash response of an auto-body structures. These objectives lead to increasing adoption of high strength steel sheet for inner and outer auto-body members. This paper evaluates the dynamic tensile characteristics of high strength steel sheets, HS45R, TRIP60, DP60 and DP100, along the rolling direction and transverse direction. Static tensile tests were carried out at the strain rate of 0.003/sec using the static tensile machine (Instron 5583). Dynamic tensile tests were carried out at the range of strain rate from 0.1/sec to 200/sec using a high speed material testing machine developed. The tensile tests acquire stress-strain relation and strain rate sensitivity of each material. The experimental results show two important aspects for high strength steels: the flow stress increases as strain rate increases; the strain hardening decreases as the tensile stress increases. The experiments also produce interesting results that the elongation does not decrease even when the strain rate increases.

• Transactions of Materials Processing
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• v.15 no.8 s.89
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• pp.556-561
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• 2006

Most of auto-body members are composed of stamping parts. These parts have the non-uniform thickness and plastic work hardening distribution during the forming process. This paper is concerned with the side impact analysis of the ULSAB-AVC model according to the US-SINCAP in order to compare the crashworthiness between the model with and without considering the forming effect. The forming effect is ca]ciliated by one-step forming analysis for several members. The crashworthiness is investigated by comparing the deformed shape of the cabin room the energy absorption characteristics and the intrusion velocity of a car. The result of the crash analysis demonstrates that the crash mode, the load-carrying capacity and energy absorption can be affected by the forming effect. It is noted that the design of an autobody should be carried out considering the forming effect for accurate assessment of crashworthiness.

• Transactions of the Korean Society of Automotive Engineers
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• v.13 no.4
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• pp.81-89
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• 2005

The response surface method is the statistical method which can be applied to the non-sensitivity based optimization. The response surface which is constructed by the least square method contains only the polynomial terms so that the global maximum and minimum points are easily obtained. In this paper, this response surface method is utilized to optimize the crashworthiness of auto-body members. As the first step, the thickness of a simple circular tube is optimized to confirm the application of the response surface method to the crashworthiness. Optimization of the thickness on the front side member is, then, performed with the constructed response surface of the absorbed energy and deformation. Optimization results demonstrate that the absorbed energy and the deformation pattern of the front side member is improved in the viewpoint of enhancement of the crashworthiness.

• Transactions of the Korean Society of Automotive Engineers
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• v.12 no.3
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• pp.204-210
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• 2004

Most auto-body members fabricated by the sheet metal forming process. During this process the thickness and material properties of the sheet metal are changed with the residual stress and plastic strain. This paper deals with the material properties of the sheet metal at the high strain rate considering the pre-strain effect. Specimens are selected from sheet metals for outer panels and inner members, such as SPCEN, SPRC45E, SPRC35R and EZNCD. The specimens are prepared with the pre-strain of 2, 5 and 10 % by tensile elongation in Instron 5583, which could be equivalent to the plastic strain in sheet metal forming. High speed tensile tests are then carried out with the pre-stained specimens at the strain rate of 1 to 100/sec. The experimental result informs that the material properties are noticeably influenced by the pre-strain when the yield stress of the specimens is moderate as SPCEN, SPRC35R and EZNCD. The result also demonstrates that the ultimate tensile strength as well as the yield stress is increased as the amount of the pre-strain is increased.