In the automotive industry, extensive research has been conducted to eliminate factors negatively impacting product quality, such as wrinkles, cracks, and thickness distribution in components. The application of drawbeads often relies on the experience of field workers, leading to considerable trial and error before stabilizing the production process. Therefore, to efficiently transform these inefficiencies related to time and cost, there is a need for real-time predictive technology for forming quality based on the position of drawbeads and the bead force. This study proposes a method for predicting formability in real-time, based on a digital twin framework that considers the position of drawbeads and holder force. A digital twin was developed to predict the sheet metal forming process using Support Vector Machine, Random Forest, Gradient Boosting Machine, and Artificial Neural Networks. The machine learning models were trained using finite element analysis data corresponding to the position and bead force of drawbeads, enabling the real-time prediction of wrinkles and crack occurrences. The accuracy of the machine learning models was demonstrated, achieving 100% accuracy in determining crack occurrence, with a mean squared error (MSE) of 0.141 for wrinkle prediction and 0.038 for crack prediction, thereby ensuring the accuracy of the forming prediction model based on drawbead applications. Based on these predictive models, a user-friendly GUI has been developed, which is expected to reduce design time and costs while facilitating real-time predictions of forming quality, such as wrinkles and cracks, on-site.

During tensile testing of materials, strain measurement is conducted using either contact or non-contact methods. Contact methods offer high accuracy and precision but are limited by the specimen's thickness and dimensions, whereas non-contact methods minimize damage to thin specimens and allow measurements in various environments, though they require longer prep-aration and calculation times. This paper proposes a circular grid marking pattern and a strain prediction algorithm using artificial intelligence (AI), which simplifies the preparation process and allows strain prediction without additional equipment. The circular grid pattern can be ar-ranged in various configurations from 1×5 to 5×7, and a laser marker, which requires minimal time, was used to engrave the pattern on the specimen to shorten the preparation time. The AI model, trained on image-based data, enables strain calculation regardless of the specimen's gauge length and size, and allows measurement of local strain as well as gauge-length strain. The reliability of this concept was verified by applying it to tensile testing.

During tensile testing of materials, strain measurement is conducted using either contact or non-contact methods. Contact methods offer high accuracy and precision but are limited by the specimen’s thickness and dimensions, whereas non-contact methods minimize damage to thin specimens and allow measurements in various environments, though they require longer preparation and calculation times. This paper proposes a circular grid marking pattern and a strain prediction algorithm using artificial intelligence (AI), which simplifies the preparation process and allows strain prediction without additional equipment. The circular grid pattern can be arranged in various configurations from 1 × 5 to 5 × 7, and a laser marker, which requires minimal time, was used to engrave the pattern on the specimen to shorten the preparation time. The AI model, trained on image-based data, enables strain calculation regardless of the specimen’s gauge length and size, and allows measurement of local strain as well as gauge-length strain. The reliability of this concept was verified by applying it to tensile testing.

Since pipes used for water pipes are thin and difficult to fasten using welding or screws, they are fastened by a crimping joint method using a metal ring and a rubber ring. In the conventional crimping joint method, the metal ring and the rubber ring are arranged side by side. However, if water leaks from the rubber ring, there is a problem that the adjacent metal ring is rapidly corroded. In this study, to delay and minimize the corrosion of connected water pipes, we propose a spaced crimping joint method in which metal rings and rubber rings are separated at appropriate intervals. This not only improves the contact performance between the connected water pipes but also minimizes the load applied to the crimping jig during crimping to prevent damage to the jig. For this, finite element analyses were performed for the crimp tool and process analysis, and the design parameters were set as the curling length at the top of the joint, the distance between the metal rings and rubber rings, and the crimp jig radius. Through FEA of 100 cases, data to be trained in machine learning were acquired. After that, training data were trained on a machine learning model and compared with a regression model to verify the model’s performance. If the number of training data is small, the two methods are similar. However, the greater the number of training data, the higher the accuracy predicted by the machine learning model. Finally, the spaced crimping joint to which the derived optimal shape was applied was manufactured, and the maximum pressure and pressure distribution applied during compression were obtained using a pressure film. This is almost similar to the value obtained by finite element analysis under the same conditions, and through this, the validity of the approach proposed in this study was verified.

The torsion beam, integral to rear suspension systems in vehicles, is a critical component where strength and durability must be prioritized in specific regions. To enhance the strength of these regions, induction hardening, a localized heat treatment method, is employed. However, the application of this treatment introduces distortion, which compromises the precision of welding between components and raises significant concerns about product quality and safety. To address these challenges, the present study introduces a front-end analysis process for induction hardening aimed at predicting distortion following heat treatment. A three-dimensional model of the product was utilized to simulate the front-end process of induction hardening. A coupled analysis of electrical and thermal fields was conducted to replicate the heating effect induced by coils during the heat treatment process. Additionally, a thermo-structural coupled analysis was performed to predict the distortion occurring during the cooling phase. A comparative analysis with actual product measurements demonstrated that the proposed method achieved a distortion displacement prediction accuracy of 98%, thereby validating the efficacy of the proposed analysis process.