The objective of this study is to find the optimal production process in the aluminum IMS core parts. To reduce the production process, the total stage was designed at a total of 2 stages and 3 stages. In the total 2 stages process, the production stage was divided into a shaft part production and a yoke part production. In the total 3 stages process, the yoke production stages were subdivided into the 2 stages for distributing the stress. The results were compared and analyzed in terms of effective stress, folding characteristics and load characteristics. The stress distributions according to the production total stages were almost the same, the yoke production stage was received high stress due to the high strain. Both the tubular shaft yoke and solid shaft yoke according to the production total stages did not have any problems in the production because there did not occur the folding, metal flow and under-fill. When the total 2 stages were employed, the load for producing the tubular shaft yoke and the solid shaft yoke was decreased by 35.0% and 27.1%, respectively. As the results, when the total 2 stages process is applied rather than 3 stages process, the product is produced quickly and it is expected to be advantageous for the production cost due to the low load.

The objective of this study is to optimize the diameter of tubular shaft yoke and solid shaft yoke, which are the core components of Al IMS for xEV. The processes of both products were designed totally 6 steps to manufactured the shaft part and the yoke part. The diameter of solid shaft yoke and tubular shaft yoke were changed from 20mm to 25mm and from 30mm to 35mm, respectively. Al 6082 was applied to the material of both products. The friction condition between die and material was employed Oil_Cold (Aluminum) with reference to the library in the program. The results were analyzed and compared in terms of effective stress, effective strain, and nodal velocity characteristics. The effective strain value for manufacturing the yoke part was higher than the shaft part because its part has a complex geometry. The value of nodal velocity was also higher with high effective strain region. However, in 6 stage process of tubular shaft yoke, although it had the high effective strain value, the nodal velocity value was the lowest due to the piercing process. The effect of shaft part diameter on effective stress in the tubular shaft was difficult to observe, however, in the solid shaft yoke, when the shaft part of one increased, the effective stress value was increased due to the larger yoke size.

The objective of this numerical study is to investigate the effect of shaft part’s diameter on the load distribution, under-fill, and metal-flow line characteristics in tubular & solid shaft yoke of Al-IMS. The outer diameter of tubular shaft yoke was changed from 30mm to 35mm, and the shaft diameter of solid shaft yoke was varied from 20mm to 25mm. In this results, the required load for production was linearly increased with increasing the tubular shaft yoke outer diameter. In the solid shaft yoke, the loads for the shaft part extending process were almost constant by 10,000kg, however, the loads for generating the yoke process, which were needed a lot of strain, were increased by 4,000kg with increasing the diameter of shaft part. The under-fill regions according to diameter of the shaft part were not observed in both products, and the metal-flow lines were also straight without folding phenomena.

The objective of this numerical study is to investigate the effect of aluminium material on the weight reduction in tubular shaft yoke and solid shaft yoke. The tubular shaft and the solid shaft were designed by 6 stage processes and the results were analyzed by using a finite element analysis method. The coefficient of friction was set to Oil_cold as referred to the analysis library. It was found that the weight was reduced as 65% with applying the aluminium alloy due to lower density than carbon steel. Von-mises stress values of applying aluminium alloy to the tubular shaft yoke and solid shaft yoke were lower than those of carbon steel because of the low yield stress of aluminium alloy. The folding and underfill phenomenon were not observed on the aluminium alloy in tubular shaft yoke and solid shaft yoke. From these results, the weight reduction of products and the extend life of dies can be expected when aluminium alloy is applied.

The objective of this study is to solve a problem that is occurred during the spline machining of tubular shaft yoke in both side IMS module. In order to simulate the problem, the movement direction of upper die was set as standard case and error case. The material of tubular shaft yoke was set to S20C as refer to the analysis library. The movement directions of upper die were separated with standard case and error case. The error case was set to simulate the problem in the spline machining of tubular shaft yoke. In order to solve the problem, the outer radius of upper die were modelled from 9.40mm to 9.44mm. The simulation results were analyzed and compared in terms of effective stress, metal flow line and folding phenomena characteristics. In case of the outer radius of upper die was 9.42mm, it was observed a relatively uniform effective stress distribution and had a straight metal flow line.

The objective of this study is to find the optimal size of splined shaft in IMS module. Two methods were used in this study. One is for the investigation of effect of indentation process on the tubular shaft yoke, and another is for the investigation of effect of indentation process on splined shaft. The spline outer size of splined shaft was increased from 0.00mm to 0.20mm. The simulation results were analyzed and compared in terms of under-fill, metal flow, effective strain, Von-mises stress and load characteristics. The indentation load was increased with increasing of spline size. However, in case of 0.15mm outer diameter increasing, the separation load was decreased. The case of 0.10mm diameter increasing was the best spline size based on the low indentation load and high separation load.

The object of this study was to investigate for improving of the homogeneous stress distribution according to sliding cage geometry. In order to achieve this, the sliding cage were modelled as type A, type B and type C, then the sliding cage were applied at A-IMS assembly. The numerical simulation was performed by SOLIDWORKS SIMULATION commercial code and the torque range was applied from 10N·m to 40N·m at A-IMS assembly. The results of simulation were compared in terms of Von-mises stress, principal stress and displacement characteristics. Each stress of type B were the highest value. In other hand, Von-mises stress of type A and type C were less than yield stress.

This study was performed for the optimizations of A-IMS assembly by analyzing the stress distributions under the different torque conditions. In order to achieve this, the numerical simulation was performed by SOLIDWORKS commercial code and the torque range that applied on the A-IMS assembly was increased from 10 N·m to 40 N·m. The simulation results were analyzed and compared in terms of Von-mises stress, principal stress, and displacement characteristics. The maximum stress distributions was observed on the contact surface of needle bearing which is located between tubular and solid shaft. It was found that the fracture of A-IMS assembly won’t occur until 30 N·m of torque. Therefore, it was concluded that there is no problem for the manufacturing of A-IMS assembly.

The objective of this work is to investigate the A-IMS structural defects on the tubular shaft and solid shaft by analyzing the under-fill, metal flow, effective stress and load characteristics. The tubular shaft and solid shaft were designed 6 stage process by upper and lower die. The results were analysed by using a finite elements analysis method. The coefficient of frictions were set Oil_Cold conditions as referred to the analysis library. It was found that the actual under-fill phenomenon was not observed in both tubular and solid shaft. The load values of tubular and solid shaft were 520ton and 255ton, respectively. These values were under the limit of forging machine maximum value.

The objective of this study is to investigate the effect of closed and open type on the load characteristics and amount of waste in tubular shaft and solid shaft for optimal design. The open and closed type were designed by 6 stage processes and applied for analysis. The coefficient of friction was set to Oil_Cold conditions as refer to the analysis library. It is found that the actual underfill phenomenon was not observed on the closed and open type. The metal flow of the closed and open type are revealed that the folding phenomenon was not occurred, thus there is no problem in actual production. The load characteristics are similar from stage 1 to stage 3 due to the same geometry of upper and lower die. However, tubular shaft and solid shaft are decreased 26% and 32% load from stage 4 to stage 6. In case of open type, amount of waste of tubular shaft and solid shaft are 11g and 14g, respectively.

The objective of this study was to investigate the optimal design on the tubular shaft and solid shaft for A-IMS of commercial vehicle. The tubular shaft and the solid shaft were designed by 6 stage processes and the results were analyzed by using a finite element analysis method. The coefficient of friction was set to Oil_Cold conditions as referred to the analysis library. It was found that the actual underfill phenomenon was not observed on the tubular shaft and solid shaft. The metal flow of the tubular shaft and solid shaft revealed that the folding phenomenon was not occurred, so there is no problem in actual production. Principal stress and load characteristics of tubular shaft were higher than those of solid shaft since the tubular shaft has many deformation from stage 1 to stage 3.

In this study, the effect of slit length on the reduction of waste material was studied numerically. At the same time, the tightening axial force between steering shaft and asymmetry pinch yoke was also studied and compared. To achieve this study, the numerical simulation was performed by AFDEX commercial code. The slit length(Ls) of pinch yoke was increased from 25mm to 34mm by the steps with an interval of 3mm. AISI 1025 was applied for the source material of asymmetry pinch yoke. Amount of deformation was applied as much as 0.1mm for tightening the pinch bolt yoke and the steering gear shaft. It was revealed that the stress of steering shaft ear in XX-direction and YY-direction showed the highest value in 34mm and 31mm of slit length cases, respectively. The stress of ZZ-direction has the same value in all cases. The tightening stress between the asymmetry pinch yoke and the shaft of steering gear had the highest value in XY-direction. In additions, when slit length was increased by the steps with an interval of 3mm, the material was more wasted approximately as much as 0.844g. In conclusions, 31mm of lit length was the optimal length in aspect of the tightening stress and the waste material.

The objective of this study is to investigate the effect of operating conditions on the performance of small HSDI compression ignition engine. Combustion and exhaust emission characteristics of engine were studied by using CFD simulation with ECFM-3Z combustion model. The conditions of simulation were varied with injection timing, injection pressure, and operating speed, and the results were compared in terms of combustion pressure, rate of heat release, NOx and soot. It was found that as injection timing was advanced and injection pressure is increased, combustion pressure and rate of heat release were increased. As a result, NOx generation is increased. Soot generation is also increased due to the wall film caused by the increase of the injection pressure and locally the rich mixture caused by the effect of the advancing of injection timing.

In this study, the effect of upper die type on the load characteristics of lower die and the wasted material was studied numerically. The different shapes(A-type, B-type, and C-type) of upper die were applied. Also finite element analysis method was applied for the analysis in each stage. The half of X, Y plane was analyzed due to the symmetrical shape in order to reduce the analysis time and be accurate results. The coefficient of friction was set to oil_cold conditions as refer to the system library. It was revealed that principal stress was the order in A, C, and B. A and B type have the highest value in 4 stage, and C type shows the highest value in 3 stage. In addition, Von mises stress were higher in order A, B, and C. A and B type have the highest in 4 stage, and C type shows to have about the same value in the 2 - 5 stage. The load was generally higher than C type. The load of C type was reduced in YY-direction at each stage without 2, 5, 6 stage.

In this study, the effect of upper die type on the load characteristics of lower die and the wasted material was studied numerically. The open and closed types of upper die were applied for each stage and the results are analyzed using a finite element analysis method. The half of x,y plane was analyzed due to the symmetrical shape in order to reduce the analysis time. The coefficient of friction was set to Soap_Cold conditions as refer to the analysis library. It was revealed that a lot of underfill portion was observed the open type in stage 4. As a result of the maximum and minimum values of the max principal stress, closed type case much receives compressive stress about 620MPa-2019MPa. In case of open type, The load was reduced in all direction at each stage