• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.6 s.237
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• pp.895-903
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• 2005

In this paper, we present a cutter location (CL) surface deformation approach for constant scallop height tool path generation from triangular mesh. The triangular mesh model of the stereo lithography (STL) format is offset to the CL surface and then deformed in accordance with the deformation vectors, which are computed by the slope and the curvature of the CL surface. In addition, the tool path which is computed by slicing the deformed CL surface is inversely deformed by those same deformation vectors to a tool path with a constant scallop height. The proposed method is implemented, and a tool path generated by the proposed method is tested by simulation and by numerical control (NC) machining. The scallop height was found to be constant over the entire machined surface, demonstrating much better quality than that of mesh slicing, under the same constraints for machining time.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.1
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• pp.87-92
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• 2010

Micromachining technology using a ultra-precision micromachining system is widely applied in the fields of optics, biotechnology and analytical chemistry, etc. specially in microfabrication of fresnel lens, light guide panels of TFT-LED and PDP ribs with micro-patterns, machining errors have an effect on the performance of those products. The deflection of tool and tool holder is known to be one of the very important factors that is due to machining errors in micromachining. The deflections of diamond tool and tool holder used in micro-grooving are analysed by FEM. We analysed by FEM. With an linearity valuation of FEM, deflection of tool and tool holder is calculated by using the data of cutting force which is acquired from micro-V groove machining experiments in micromachining system.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.121-127
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• 2008

Micro end-milling has been becoming an important machining process to manufacture a number of small products such as micro-devices, bio-chips, micro-patterns and so on. Despite the importance of micro end-milling, many related researches have given grand efforts to micro end-milling phenomenon, for example, micro end-milling mechanism, cutting force modeling and machinability. This paper strongly concerned actual problem, micro tool deflection, which causes excessive machining errors on the workpiece. To solve this problem, machining error prediction method was proposed through a series of test micro cutting and analysis of their SEM images. An iterative algorithm was applied in order to obtain corrected tool path which allows reducing machining errors in spite of tool deflection. Experiments are carried out to validate the proposed approaches. In result, remarkable error reduction could be obtained.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.6
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• pp.43-51
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• 2004

A method for form error prediction in side wall machining with a flat end mill is suggested. Form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. Developed model can predict the surface form error about three hundred times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.781-785
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• 2005

Cutting forces and tool deflection in end milling are represented as the closed form of tool rotational angle and cutting conditions. The discrete cutting forces caused by tool entry and exit are continued using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping pan are considered for cutting forces and tool deflection estimation. Compared to numerical methods, the presented method has advantages in short prediction time and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the ferm accuracy is easily predicted by tool deflect ion curve.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.898-901
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• 2000

In this paper, the theoretical tool displacement and surface roughness are analyzed based on the tool locus of a 2-dimensional tool vibrator. At first, the effects assuming no structural deformation of such variables as frequency, amplitude and phase difference that determine tool loci are simulated. The results show that larger amplitude and/or higher frequency makes better surface. However, a real tool vibrator has the structural deformation, much or less, depending on the excitation frequency. Applying FEM analysis to the deformation of a designed 2D tool vibrator according to the excitation, it has been proved that in this case the displacement is 5${\mu}{\textrm}{m}$ at 1KHz and almost 0 at 20KHz even under the same excitation amplitude.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.11
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• pp.137-144
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• 1998

In this paper we present our research dealing with the problem of tool deflection during the milling. We try to compensate the errors by considering a new tool trajectory. In order to determine the compensated tool trajectory, the problem is divided in three steps : cutting forces model, tool deflection model and trajectory compensation. Starting from experimental data, we determine a cutting forces model., which allows us to anticipate the tool deflection along one nominal path. In order to determine the compensated tool trajectory, we propose in this paper a method of path compensation, called “mirror method”. This method of tool path optimization allows to minimize errors due to tool deflection. Several examples are processed in simulations and validated experimentally.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.119-124
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• 1996

End milling operation is very important in machining precision components. Deterioration of surface roughness and surface geometry will cause more process for surface finishing. According to the feed rate and the cutting edge geometry, the cusp which is geometrically uncut surface is determined. To reduce the cost for dinishing operation after end milling, the cusp must be remaianed in small size as possible. Due to the cylindrical type of the end mill, tool deflection is one of the main problems in surface generation. The cutting resistance and the rigidity of the end mill will determine the size of tool deflection. One more important factor which deteriorate surface quality comes from the error in manufacturing end mills. Run-out of end mill which is the difference of the radius of each cutting edges will produce the difference of the cusp size in every rotation of end mill. These three major factors to the surface quality will be analized and the result will be compared with experimental ressult.

• Journal of the Korea Institute of Information and Communication Engineering
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• v.26 no.7
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• pp.981-988
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• 2022

The intelligent production plant called smart factories that apply information and communication technology (ICT) are collecting data in real time through various sensors. Recently, researches that effectively applying to these collected data have gained a lot of attention. This paper proposes a method for the tool condition monitoring based on the sound signal generated in machining process. First, it not only detects a fault tool, but also presents various tool states according to idle and active operation. The second, it's to represent the power spectrum of the sounds as images and apply some transformations on them in order to reveal, expose, and emphasize the health patterns that are hidden inside them. Finally, the contrast-enhanced PSD image obtained is diagnosed by using CNN. The results of the experiments demonstrate the high discrimination potential afforded by the proposed sound PSD image + CNN and show high diagnostic results according to the tool status.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2011.06a
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• pp.29-30
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• 2011