• Journal of the Korean Society of Manufacturing Process Engineers
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• v.4 no.4
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• pp.14-20
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• 2005

This paper deals with the study of feasibility of rotary carbide tools in the machining of aluminium alloy. A rotary tool holder was designed and manufactured for this work. Experiments were performed using Taguchi methods and regression analysis to analyse the influence of various factors and their interactions on the cutting characteristics of rotary carbide tools during machining. The cutting force is influenced the most greatly at the inclination angle. The surface roughness is influenced distinctly at depth of cut. It deduced an equation to predict cutting force and surface roughness. Hence, it could be concluded here that the proposed model agrees with the experimental data satisfactorily.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.2
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• pp.169-177
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• 1997

In this study, investigated are the effects of tool rake angles and the change of cutting conditions on the specific cutting pressure in face milling. The cutting force in face milling is predicted from the double cutting edge model in3-dimensional cutting. Conventional specific cutting pressure model is modified by considering the variation of tool rake angles. Effectiveness of the modified cutting force model is verified by the experiments using special face milling cutters with different cutter pockets and various rake angles. From the comparison of the presented model and the specific cutting pressure, it is shown that the axial force can be predicted by the tangential force, radial force and geometric conditions. Also, the rela- tionship between specific cutting pressure and cutting conditions including feedrate, cutting velocity and depth of cut is studied.

• Journal of the Korean Society for Precision Engineering
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• v.10 no.4
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• pp.206-215
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• 1993

The finite element method is applied to analyze the mechanism of metal cutting, especially micro metal cutting. This paper introduces some effects, such as constitutive deformation laws of workpiece material, friction of tool-chip contact interfaces, tool rake angle and also simulate the cutting process, chip formation and geometry, tool-chip contact, reaction force of tool. Under the usual plane strain assumption, quasi-static analysis were performed with variation of tool-chip interface friction coefficients and tool rake angles. In this analysis, cutting speed, cutting depth set to 8m/sec, 0.02mm, respectively. Some cutting parameters are affected to cutting force, plastic deformation of chip, shear plane angle, chip thickness and tool-chip contact length and reaction forces on tool. Several aspects of the metal cutting process predicted by the finite element analysis provide information about tool shape design and optimal cutting conditions.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.12
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• pp.72-80
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• 1995

Ultraprecision machining technology has been playing a rapidly increasing and important role in manufacturing. However, the physics of the micromachining process at very small depth of cut, which is typically 1 .mu. m or less is not well understool. Shear along the shear plane and friction at the rake face dominate in conventional machining range. But sliding along the flank face of the tool due to the elastic recovery of the workpiece material and the effects of plowing due to the large effective negative rake angle resultant from the tool edge radius may become important in micromachining range. This paper suggests an orthogonal cutting model considering the cutting edge radius and then quantifies the effect of plowing due to the large effective negative rake angle.

• Journal of Advanced Marine Engineering and Technology
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• v.35 no.1
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• pp.75-81
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• 2011

Dissimilar joining of aluminum 6061-T6 alloy to aluminum 5083-O alloy was performed using friction-stir welding technique. The mechanical properties, hardness, macro- and micro-structure on dissimilar friction-stir-weld aluminium alloy were investigated. Mechanical properties of the weld mainly depend on which Al alloy is placed at the retreating sides of the rotating tool respectively during dissimilar friction-stir weld because the microstructure of stir zone was mainly composed of welded Al alloys of the retreating side. Onion ring pattern was observed like lamella structure stacked by each Al alloy in turn. It apparently results in defect-free weld zone that traverse speed was changed to 124 mm/min under conditions of tool rotation speed like 1250 rpm with 5 mm of tool's prove diameter, 4.5 mm of prove length, 20 mm of shoulder diameter, and $2^{\circ}$ of tilting angle. The 231 MPa of ultimate stress and the 121 MPa of yield point are obtained about the friction-stir-welded Al 6061-T6(AS) to Al 5083-O(RS).

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.346-351
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• 2001

The technique of high speed machining is widely studied in machining field. Because the high efficiency and accuracy in machining can be obtained in high speed machining. Unfortunately the development of tool for high speed machining is not close behind that of machining tool. So in this study, we made 4 types flat end mill for obtaining data according to tool shape. Especially, we concentrated in helix angle and number of cutting edge. First we confirmed cutting condition by several experiments and measuring cutting force, tool life, tool wear and chip shape according to cutting length. In results, we acquired the fact that 45 degree helix angle and six cutting edge tool is suitable for high speed machining.

• Proceedings of the Korean Vacuum Society Conference
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• 2011.08a
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• pp.270-270
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• 2011

전이금속(transition metal) 질화물(nitride)은 높은 경도, 내마모성, 부식 저항성 그리고 내열성 등과 같은 우수한 기계적 물성 때문에 많은 연구가 되어 왔다. 이 중 질화 티타늄은 높은 경도, 내식 및 내마모의 우수한 기계적 특성으로 공구(tool)와 같은 제품의 수명 향상을 위한 표면 코팅소재로 사용되어 왔으며, 금(gold)색의 미려한 색상을 이용한 제품의 외관 표면처리와 인체에 무해한 특성을 활용한 정형외과 및 치과용 보형물의 수명 및 안정성 향상 등 다양한 분야에 응용 되고 있다. 본 연구에서는 아크방전을 이용한 경사 코팅법으로 질화 티타늄을 합성하였으며, 경사 코팅에 따른 단층 및 다층 박막(2~3 layer)의 미세조직 변화와 그 물성을 평가하였다. 아크 소스에 장착된 타겟은 120 $mm{\Phi}$, 99.5%의 Ti 타겟을 사용하였고, 시편과 타겟 간의 거리는 약 30 cm이며, 시편은 냉연강판과 SUS를 사용하였다. 시편을 진공용기에 장착하고 ~10-6 Torr까지 진공배기를 실시하고, Ar 가스를 진공용기 내로 공급하여 ~10-4 Torr에서 시편에 bias (Pulse : 400 V)를 인가한 후 아크를 발생시켜 약 5분간 청정을 실시하였다. 플라즈마 청정이 끝나면 시편에 인가된 bias를 차단하고 코팅하였다. 경사 코팅을 위한 시편의 회전각은 45$^{\circ}$, -45$^{\circ}$이며, 질화 티타늄의 두께는 약 3 ${\mu}m$로 동일하게 코팅 하였다. 45$^{\circ}$ 단일층의 경우 0$^{\circ}$ 단일층보다 경도가 감소하나 zigzag 구조의 다층으로 갈수록 45$^{\circ}$ 단일층과 비교하여 확연히 경도가 증가함을 볼 수 있었다. 다층 질화 티타늄의 경사 코팅을 통해 박막의 미세조직 변화를 SEM 이미지를 통해 확인하였으며 증착 방식에 따라 경도, 조도, 반사도 등의 물성 변화가 나타났다. 본 연구에서 얻어진 결과를 이용하여 다양한 형태의 박막구조 제어를 통한 물성변화가 가능할 것으로 예상된다.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.393-398
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• 2001

The technique of high speed machining is widely studied in machining fields, because the high efficiency and accuracy in machining can be obtained in high speed machining. Unfortunately the development of tool for high speed machining in not close behind that of machine tool. In this study, several types flat endmill is prepared for obtaining data according to tool shape. Especially, we concentrated in helix angle, number of cutting edge, rake angle and relief angle. Machinability is measured by cutting force, tool life, tool wear, chip shape and surface roughness according to cutting length. 3-axis cutting forces are acquired from the invented tool dynamometer for high speed machining. Particularly, we found out that the axial cutting force waveform has a good relation with tool wear features. By above results, it is suggested the endmill tool with $45^{\circ}$ helix angle, 6 cutting edge, $-15^{\circ}$ rake angle and $12^{\circ}$ relief angle be suitable for high speed machining

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.5-14
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• 2002

Hemisphere shapes were machined for different tool paths and machining conditions with ball endmill cutters. It was also found out how feedrate affect the precision of the machining and also tried to study the most suitable feedrate in specific cutting condition. Tool deflection, cutting forces and shape accuracy were measured according to the inclination position of the sculptured surface. As the decreasing of inclination position angle, the tool deflection was increased due to the decreased cutting speed when the cutting edge is approaching toward the center. Tool deflection when upward cutting IS obtained less than that of downward cutting and down-milling in upward cutting showed the least tool deflection for the sculptured surface. For down-milling, the cutting resistance of the side wall direction is larger than that of feed direction. It was found that the tool deflection is getting better as tool path is going to far from the center for convex surface.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.2
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• pp.17-24
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• 2004

In end milling process, undeformed chip thickness and cutting forces vary periodically with phase change of the tool. Recently, a model has been proposed to simulate the shear and friction characteristics of an up-end milling process in terms of the equivalent oblique cutting to this. In the current study, a down-end milling process has been replaced with the equivalent oblique cutting process. And shear and tool-chip friction characteristics variation of SM45C steel has been studied using the end-mills of different helix angles. The specific shear and friction energy consumed with helix angle of $50^{\circ}$ is somewhat larger than those of$30^{\circ}$ and $40^{\circ}$. The specific shear energy consumed is about 76-77% of the specific cutting energy regardless the helix angles.