The sub-frame is located on the lower body of a monocoque type vehicle and serves as an engine and suspension, and is an important object part that receives a lot of load. The existing press-type sub-frame has a large number of parts for assembling, which causes an increase in cost. Changing the machining form of this part from the existing press-type machining method to the hydro-forming machining method has the advantage of reducing the cost and weight at the same time due to the reduction of the process. Therefore, in this study, the purpose of this study is to change the design so that the sub-frame of the existing press type can be changed to the hydro-forming process method. To this end, we intend to present a design method by analyzing the effect on the rigidity of the sub-frame using the existing machining method through shape optimization analysis.

Gas springs applied to various industrial fields are generally composed of a cylinder, a piston rod, a cover, and a seal mount. Because of the thin wall of the cylinder, small gas springs are manufactured using a roller forming process that presses the cylinder wall into a groove of cover in the cylinder. In this study, finite element analysis and process design of roller forming are performed to systematically manufacture the small gas spring and develop a roller forming machine. In order to perform roller forming analysis, tensile tests of structural steel pipe are performed and mechanical properties are analyzed. Roller forming process parameters such as radius and depth of roller grooves are derived using the incompressible condition of plastic deformation theory and the results of finite element roller forming analysis. Using the derived roller shape, a roller forming machine is developed and prototypes of the small gas spring are manufactured. Finally, the dimensional accuracy of the manufactured gas spring prototypes is analyzed through three-dimensional shape measurement.

Although most of the automobile bodies are made of steel, the application of aluminum alloy sheet with high strength is under consideration for the development of environmentally friendly lightweight body for fuel economy improvement and carbon dioxide emission reduction. In the case of some inner plates, application of magnesium alloy sheet is examined. TRB plate has been studied mainly for weight reduction and rigidity reinforcement of steel plate parts. Recently, research on aluminum TRB rolled plate for light and environment friendly automobile application has been started, It is expected that the development of eco - friendly TRB rolling material made of light alloy will increase as the importance of light weight body for future energy efficiency increases. Therefore, in this study, we tried to obtain the technology to improve the quality of the product by pre - verifying the cooling performance of the hot forming process through the heat flow analysis and evaluating the cooling performance through the temperature distribution analysis. As a result, it was found that the temperature distribution through the flow velocity problem and the flow of the cooling channel can influence the quality of the final product through different heat distribution and cooling time depending on the shape of the mold and the product.

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Compared to conventional sheet forming processes, ISF is of a clear advantage in manufacturing small batch or customized parts. ISF needs die-less machine alone, while conventional sheet forming requires highly expensive facilities like dies, molds, and presses. This equipment takes long time to get preparation for manufacturing. However, ISF does not need the full facilities nor much cost and time. Because of the facts, ISF is continuously being used for small batch or prototyping manufacturing in current industries.However, spring-back induced in the process of incremental forming becomes a critical drawback on precision manufacturing. Since sheet metal, being a raw material for ISF, has property to resilience, spring-back would come in the case.It is the research objective to investigate how geometrical shaping parameters make effect on shape dimensional errors. In order to analyze the spring-back occurred in the process, this study experimented on Al 1015 material in the ISF. The statistical tool employed experimental design with factors. The table of orthogonal arrays of L8 (27) are used to design the experiments and ANOVA method are employed to statistically analyze the collected data. The results of the analysis from this study shows that the type of shape and the slope of bottom are the significant, whereas the shape size, the shape height, and the side angle are not significant factors on dimensional errors. More error incurred on the pyramid than on the circular type in the experiments. The sloped bottom showed higher errors than the flat one.

The objective of this study is to predict the formability of sheet metal for the bladder press. The static implicit finite element method is applied effectively to analyze bladder forming processes using AutoForm software. The material used for forming analysis is AL2024, and the thickness of the plate is 1.6mm, 1.8mm and 2.0mm. Forming force is shown by 101.92kN～87.22kN. The result from the simulation analysis was applied to the bladder press system.

In this study, Intersecting Tensegrity System that is integrated solid compression members with tension members was presented. This system is set up by connecting upper and lower compression members of pyramid shape with exterior tension members. In this system, the solid compression members are intersected each other and connected by a tension member in the center. This system is a variation of Tensegrity system, has a improved feature that the system is able to induce prestresses in all of tension members easily by adjusting the distance of a tension member in the center. The proposed system was studied by modeling, and the structural behavior of the system was investigated by mechanical analysis of the model. Furthermore, the features of the structural behavior variations was investigated when the composition elements(total height, size of surface, intersection length, etc.) are changed variously. It was also showed that the system is able to be used as a temporary space structure system with a membrane roof of inverse conical shape.

In order to predict droplet velocity and temperature profiles and fractional solidification with flight distance during spray forming, the Newtonian heat transfer formulation has been coupled with the classical heterogeneous nucleation and the specific solidification process. It has been demonstrated that the thermal profile of the droplet in flight is significantly affected by process parameters such as droplet size, initial gas velocity, undercooling. As the droplet size and/or the initial gas velocity increase, the onset and completion of solidification are shifted to greater flight distances and the solidification process also extends over a wider range of flight distances. The amounts of solid fractions formed during recoalescence, segregated solidification and eutectic solidification are insensitive to droplet size and initial gas velocity whereas those are strongly affected by the degree of undercooling. There are good linear relations between the undercooling and the corresponding solid fractions generated during recoalesced, segregated and eutectic stages.

The main objective of this research was to evaluate the effects of process variables which were forming ability, flow displacement, effective stress, effective strain, fluid vector and products defects on manufactured artificial lightweight aggregate made of both incinerated sewage sludge ash and clay by means of the numerical analysis of a rigid-plastic finite element method. CATIA (3D CAD program) was used for an extrusion metal mold design that was widely used in designing aircraft, automobile and metallic molds. A metal forming analysis program (ATES Co.) had a function of a rigid-plastic finite element method was used to analyze the program. The result of extrusion forming analysis indicated clearly that a shape retention of the manufactured artificial lightweight aggregate could be maintained by increasing the extrusion ratio (increasing compressive strength inside of extrusion die) and decreasing the die angle. The stress concentration of metal mold was increased by increasing an extrusion ratio, and it was higher in a junction of punch and materials, friction parts between a bottom of the punch and inside of a container, a place of die angle and a place of die of metal mold. Therefore, a heat treatment as well as a rounding treatment for stress distribution in the higher stress concentration regions were necessary to extend a lifetime of the metallic mold. A deformity of the products could have made from several factors which were a surface crack, a lack of the shape retention and a crack of inside of the products. Specially, the surface crack in the products was the most notably affected by the extrusion ratio.