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    • Numerical Investigation of Aluminum Extrusion of Feeder and Porthole Dies for Solid Profiles with Massive Wall Thickness Variation
    Authors: Quang-Cherng Hsu; Vinh -Hung Tran; Anh-Tuan Do; Tat-Tai Truong;  Advisor: -;  Co-Author: - (2022)

    Design of extrusion dies for complex solid profiles with varying wall thickness to ensure the flow balance in the extrudate is difficult. The type of dies and their structure, which directly affect the quality of the extruded product, are significantly influenced by experience of the designer. In this study, two types of dies, including feeder die and porthole die, were designed for extruding a complex heatsink profile. The basic dimensions of the feeder die were similar to the porthole die except for the bridge structure. Steady-state extrusion simulations of these two dies using HyperXtrude software were carried out. The numerical analysis results revealed that the porthole die with a unique bridge design offered a better distribution of velocity and residual stress in the extruda...
    • Quality Assessment of Freeform Surface Manufactured by CNC Milling Using Point Cloud Data Obtained from Different Scanning Devices
    Authors: Vinh-Hung Tran; Tat-Tai Truong; Khac-Khanh Bui; Hong-Ky Le;  Advisor: -;  Co-Author: - (2022)

    Mechanical elements with freeform surfaces are very common in aerospace, automotive, mold and die industries. With increasing demand for higher quality of freeform surfaces in many different applications, quality monitoring and evaluation of freeform surfaces have become of great concern in modern manufacturing. In this study, quality evaluation of a freeform surface manufactured by CNC milling was carried out. First, the point cloud data of a given freeform surface sample manufactured by stamping were acquired by using different scanning systems, namely HandySCAN 3D 700 and ATOS Compact Scan 5M. Based on the point cloud data, the toolpaths, including roughing, semi-finishing, and finishing, were generated using computer-aided manufacturing (CAM) software. Milling experiments were t...