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Numerical Simulation of Chip Ploughing Volume in Micro Ball-End Mill Machining
Shan Luo,Abdolreza Bayesteh,고정혁,Zuomin Dong,Martin B. Jun 한국정밀공학회 2017 International Journal of Precision Engineering and Vol.18 No.7
Chip ploughing becomes a more serious problem in micro-machining due to its relatively large size with respect to the finished part, negatively impacting on the accuracy of the finished surface. In this work, a 3D geometry model of the chips generated during micro ball-end milling is introduced to accurately calculate the chip ploughing volume to support needed tool path adjustments for ensured accuracy of the finished part. A new method is developed to compute the chip ploughing volume by dividing the modeled chip into many discrete pieces over a ploughing dominated region and a shearing dominated region. Two simulation methods for calculating the chip volume for two example tool paths are presented. Different axial depths of cut, spindle speed and feed rate are tested to study the ploughing mechanism and reduce the ploughing effects. Experiments of cutting force measurement are used to compare with the changes of the simulated ploughing and shearing volume.
3-Axis Milling Algorithm Development for Carbon Fiber Reinforced Polymer (CFRP) Composites
Shan Luo(루오산),Reza Bayesteh(바예스테레자),Zuomin Dong(동주민),Martin B.G. Jun(전병국) Korean Society for Precision Engineering 2016 한국정밀공학회지 Vol.33 No.6
The simulation of Carbon fiber reinforced polymer (CFRP) machining facilitates the selection of optimal cutting parameter for high machining efficiency and better surface quality. In this study, This paper proposes a dual-dexel model to represent the fiber laminate with computational geometry method to calculate the fiber length removed per revolution and fiber cutting angles. A flat end milling simulation software is developed in C# to simulate and display the CFRP milling process. During simulation, fiber lengths, fiber cutting angle and engaged cutting angle can be displayed in real-time. A CFRP plate with different angles in different layer is used to compare the simulation results.
Development of a metamodel assisted sampling approach to aerodynamic shape optimization problems
Amir Safari,Adel Younis,Gary Wang,Hirpa Lemu,Zuomin Dong 대한기계학회 2015 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.29 No.5
A new metamodel-assisted sampling search approach applied to the aerodynamic shape optimization of turbomachinery airfoils is presentedin this paper. The proposed methodology integrates a non-uniform rational B-spline (NURBS) geometry representation, a twodimensionalflow analysis, and an improved metamodel driven optimization algorithm named approximated promising region identifier(APRI), which represents a momentous advancement of the existing space exploration techniques specifically for the high-dimensionalexpensive black-box (HEB) problems. The novel optimization method prospects the whole design space by generating sample points,reporting evaluating information using a surrogate model, and then focusing the search in the most promising region by deploying moreagents. Using the integration of these adaptive tools and methods, the optimization results are considerably promising in terms of computationalefficiency and performance enhancement of the turbomachinery blade airfoil shape in both design and off-design conditions.