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http://dx.doi.org/10.7735/ksmte.2012.21.3.387

A Study On Prediction Model of Cutting Conditions for Draft Angle Control  

Cho, Ji-Hyun (인천대학교 대학원 기계시스템공학부)
Song, Byeong-Uk (인천대학교 대학원 기계시스템공학부)
Seo, Tae-Il (인천대학교 기계시스템공학부)
Publication Information
Journal of the Korean Society of Manufacturing Technology Engineers / v.21, no.3, 2012 , pp. 387-393 More about this Journal
Abstract
It is very difficult to determine suitable cutting conditions in order to obtain accurate cutting profiles because machining errors caused by tool deflection depend upon cutting conditions. In this study the relationship between real cutting profiles (inclined shapes and machining errors) and cutting conditions was modeled in order to fabricate draft angle on micro molds. CCD (Central Composite Design) of DOE (Design Of Experiment) and RSM (Response Surface Method) were applied in order to model the relationship between cutting conditions and machining errors. In order to use CCD the range of radial depth of cut was chosen by $10-90{\mu}m$ and the range of feedrate was chosen by 200-300mm/min, and 9 points of cutting conditions were chosen inside determined ranges. Then, actual cutting processes were carried out as respect to 9 points of cutting conditions, draft angles and real cutting profiles were measured on cutting profiles, each response surface function was determined by conducting response surface analysis and the functions were represented by 3-dimensional graphs, contour lines and $101{\times}101$ matrices. Consequently it is possible to determine suitable cutting conditions in order to obtain arbitrary given draft angles and cutting profiles by using modeling. To validate proposed approach in this study suitable cutting conditions were determined by modeling in order to obtain arbitrary given draft angle and cutting profile, and actual cutting processes were carried out. About 95% of good agreement between predicted and measured values was obtained.
Keywords
Micro end milling; Machining error; Draft angle; Central composite design; Response surface method;
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Times Cited By KSCI : 2  (Citation Analysis)
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