Recently, lightweight materials centered on the future mobility industry are used in various parts such as battery housings and EV platform frames to improve fuel efficiency of automobile engines. Polycrystalline Diamond (PCD) tools are in demand by parts processing companies to improve productivity for machining lightweight parts. PCD drills have excellent cutting performance and wear resistance in high-speed machining. They are expected to grow in the global cutting tool market in the future. Research is needed to improve their performance. In this study, PCD gun drill and twist drill were respectively manufactured using brazing technology. Comparative machining experiments were then conducted. The PCD gun drill is a straight-shaped tool with a PCD tip brazed to a tool body groove for the tip to enter the cutting edge. The PCD twist drill is a spiral-shaped tool with a PCD drill blank brazed to a V-shaped butt joint with the tool body and an internal groove. Both PCD drills were successfully manufactured and evaluated for dimensional accuracy and surface quality by machining aluminum alloy materials with MCT equipment. In the future, we will evaluate not only aluminum materials, but also various machining materials.
Recent advancements in science and technology have enabled even microsatellites to perform various high-level tasks. As the range of missions that satellites undertake expands, even microsatellites now require thrust systems for orbit adjustment and collision avoidance. In such satellite applications, sizes and weights of all electrical components and propulsion systems are restricted, emphasizing the importance of miniaturization and weight reduction. Research is ongoing in various methods to address these needs. To solve these challenges, this study proposed a design model for miniaturizing and lightening both Anode Power Module (APM) and gas supply system. The APM utilizing an LLC resonant converter achieved an efficiency of up to 86%. An evaluation of flow control characteristics of the proposed gas supply device showed that the flow control error was less than 2.3%, indicating effective results. A thermal mass flow sensor was developed to measure the flow of gas. Temperature characteristics derived from experiments were analyzed to assess their applicability to electric thruster systems for satellites.
In recent years, the demand for lightweight parts has been gradually increasing, particularly in the E-mobility industry. Among lightweight materials, aluminum alloys are highly beneficial for improving the fuel efficiency of automobile engines due to their lighter weight compared to iron-based materials. As electric vehicles become more prevalent, aluminum alloys are also extensively used in components such as battery housings and EV platform frames. To enhance productivity, aluminum parts processing companies require Polycrystalline Diamond (PCD) cutting tools for high-speed and ultraprecision processing. PCD cutting tools are known for their excellent cutting performance and wear resistance in highspeed aluminum machining, and they are anticipated to have significant growth potential in the global cutting tool market. In this study, we manufactured three types of PCD cutting tools (Drill, Endmill, and Reamer) using a self-developed brazing device and analyzed the machining surface quality through experiments. The results showed that the brazing joint quality of the PCD cutting tools was high, and the differences in surface roughness values under various machining conditions were minimal, confirming no issues with machining performance. Future research will focus on evaluating machining precision and tool life through comparative experiments with advanced PCD cutting tools from overseas.
Owing to recent advances in additive manufacturing technology, design for additive manufacturing (DfAM) has been used to overcome design limitations due to constraints in traditional manufacturing processes. In this study, we applied DfAM technology to design lightweight and consolidated vacuum grippers for inspection equipment. We proposed a consolidated design to reduce manufacturing time and costs, which previously encompassed assembling eleven components. Topology optimization was used to reduce part weight while maintaining structural rigidity and safety, and two optimization models were designed: two-piece and one-piece models. Based on these optimized geometries, the internal vacuum paths were designed in a curved shape to enhance adsorption characteristics. Numerical simulations were conducted to evaluate the structural performance and flow characteristics of the initial design and the two optimization models. The pressure drop of the one-piece model, which was the best design, was reduced to 1/8 of the initial design and the structural safety factor was predicted to be 6.37. This final design was then additively manufactured by a digital light processing type 3D printer and the weight of the resulting parts was reduced from 12.94 to 2.08 g. Experimental observation found that the additively manufactured vacuum gripper showed enhanced absorption performance compared to the initial design.
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The development of the lightweight sandwich plate with periodically repeated cores is one of hot issues to reduce the weight of the part. The behavior of the sandwich plate under static and dynamic loads is greatly influenced by the design of the cores. The aim of this paper is to investigate the effects of the corrugated angle on low velocity impact characteristics of the lightweight sandwich plate with corrugated cores. The corrugated core with the fold surface is designed to improve the joining characteristics between cores and skin sheets. The corrugated angle of the corrugated cores ranges from 45o to 90o. Specimens are manufactured from the fused deposition modeling (FDM) process. The characteristics of the fabricated specimen are investigated. Impact experiments are performed using a drop impact tester with a stretching type of fixture and the hemispherical nose of the impact head. From the results of the experiments, the influence of the impact energy and corrugated angle on the failure pattern of the lightweight sandwich plate is examined. The effects of the corrugated angle on critical impact energies for different failure patterns are investigated. Finally, the failure map of the lightweight sandwich plate with corrugated cores is estimated.
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