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      • KCI등재

        Experimental Investigation of Concave and Convex Micro-Textures for Improving Anti-Adhesion Property of Cutting Tool in Dry Finish Cutting

        Zhengyang Kang,Yonghong Fu,Yun Chen,Jinghu Ji,Hao Fu,Shulin Wang,Rui Li 한국정밀공학회 2018 International Journal of Precision Engineering and Vol.5 No.5

        Tool-chip adhesion impacts on cutting performance significantly, especially in finish cutting process. To promote cutting tools’ anti-adhesion property, the concave micro-grooves texture (MGT) and convex volcano-like texture (VLT) were fabricated separately on lathe tools’ rake faces by laser surface texturing (LST). Various orientations of MGT and different area densities (9% and 48%) and regions (partial and full) of VLT were considered in textured patterns designing. The following orthogonal cutting experiments, machining of aluminum alloy 5038, analyzed tools’ performances including cutting force, cutting stability, chip shape, rake face adhesion and abrasion. It indicated that under dry finish cutting conditions, MGT contributed to cutting stability and low cutting forces, meanwhile friction and normal force reduced by around 15% and 10%, respectively with a weak correlation to the grooves’ orientation. High density VLT tools, on the other hand, presented an obvious anti-adhesion property. A 5 µm reduction of crater wear’s depth can be observed on textured rake faces after long length cutting and textured rake faces presented half size of BUE regions comparing to the flat tool, however, once the texture morphologies were filled or worn, the anti-adhesion effect could be invalid. The bearing ratio curve was employed to analysis tool-chip contact and durability of textured surfaces contributing to a better understanding of anti-adhesion and enhanced durability of the textured tools.

      • KCI등재

        Novel Collaborative Design Method for Lightweight Optimization Design of Vehicle Load-Bearing Parts

        Zhou Dashuang,Kang Zhengyang,Su Xiaoping 한국자동차공학회 2023 International journal of automotive technology Vol.24 No.5

        The design of new energy vehicle load-bearing structural components using traditional experience may lead to low material utilization efficiency. This makes it difficult to reduce the quality, or material shortage, which will increase the number of product design iterations and design cycle. Fortunately, the increasingly mature structural topology optimization technology can effectively solve this problem, and can provide a structural basic feature with high material utilization efficiency for parts according to the structural optimization objective. In addition, the rapid development of special casting technology makes it easier to process parts with complex shapes. Herein, a collaborative design method combining structural topology optimization design, material lightweight design and squeeze casting process was proposed to realize the lightweight of new energy vehicle load-bearing structural parts more effectively. The collaborative design method was applied to the steering knuckle design of a vehicle, and the results show that the method has a significant lightweight effect and can obtain the aluminum alloy steering knuckle with better quality.

      • KCI등재

        Geometrical Simulation Model for Milling of Carbon Fiber Reinforced Polymers (CFRP)

        Xingyu Fu,송경은,Dong Min Kim,Zhengyang Kang,Martin Byung-Guk Jun 한국정밀공학회 2022 International Journal of Precision Engineering and Vol.23 No.11

        This paper proposes a geometrical 3D milling simulation algorithm for Carbon Fiber Reinforced Polymer (CFRP) milling. In this simulation model, milling tools are simplified into layers of circles while CFRP lami- nates are simplified into layers of Dexel lines, which can realize simulations for various complex milling conditions. Significant geometrical parameters, for ex-ample, cutting angle and cutting length, can be computed with high efficiency. With some geometry-related physical models, the machining results can be pre-dicted for the entire milling process. The effectiveness of this simulation model has been validated by the milling force prediction and the delamination pre-diction. The performance of this simulation model benefits industrial CFRP manufacturing and provides a new method for online or long-time-interval simulation of CFRP machining.

      • KCI등재

        An finite element analysis surrogate model with boundary oriented graph embedding approach for rapid design

        Fu Xingyu,Zhou Fengfeng,Peddireddy Dheeraj,Kang Zhengyang,Jun Martin Byung-Guk,Aggarwal Vaneet 한국CDE학회 2023 Journal of computational design and engineering Vol.10 No.3

        In this work, we present a boundary oriented graph embedding (BOGE) approach for the graph neural network to assist in rapid design and digital prototyping. The cantilever beam problem has been solved as an example to validate its potential of providing physical field results and optimized designs using only 10 ms. Providing shortcuts for both boundary elements and local neighbor elements, the BOGE approach can embed unstructured mesh elements into the graph and performs an efficient regression on large-scale triangular-mesh-based finite element analysis (FEA) results, which cannot be realized by other machine-learning-based surrogate methods. It has the potential to serve as a surrogate model for other boundary value problems. Focusing on the cantilever beam problem, the BOGE approach with 3-layer DeepGCN model achieves the regression with mean square error (MSE) of 0.011 706 (2.41% mean absolute percentage error) for stress field prediction and 0.002 735 MSE (with 1.58% elements having error larger than 0.01) for topological optimization. The overall concept of the BOGE approach paves the way for a general and efficient deep-learning-based FEA simulator that will benefit both industry and Computer Aided Design (CAD) design-related areas.

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