• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.6
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• pp.1456-1464
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• 1993

The achievable machining accuracy depends upon the level of the micro-engineering, and the dimensional tolerances in the order of 10 nm and surface roughness in the order of 1 nm are the accuracy targets to achieved today. Such requirements cannot be satisfied by the conventional machining processes. Single point diamond turning is one of the new techniques which can produce the parts with such accuracy limits. The aims of this thesis are to get a better understanding of the complex cutting forces. A cutting model for describing the influence of cutting conditions (cutting speed, feedrate and depth of cut), material properties of the workpiece and tool geometry has been proposed after estimating the two cutting force models-the Recht model and the Dautzenberg model. The experiments with Al-alloy workpieces, which have been carried out in order to estimate the models, show that the proposed model in this thesis is better than the two models. As the depth of cut and feedrate are increased in the operations settings (depth of cut 8-100$\mu{m}$, feedrate 8-140$\mu{m}$/rev, and cutting speed 8 m/sec), the relation of dimensionless cutting forces from experiments are similar to the proposed model. With the undeformed chip area of $30-80{\times}10^{2}$\mu{m}^2$, the experimental cutting forces accord with the force prediction.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.7
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• pp.94-100
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• 1999

This study adopted the ultra precision machining system which was composed of an air bearing spindle, a granite bed, air pad and a linear feeding mechanism. It also applied the cutting experiment on the aluminum alloy. To evaluate the safety of high speed machining, we examined the surface roughness according to the changes of cutting speed and obtained the speed limit. This paper also studied the effect of cutting condition such as feed rates and depths of cut on the surface roughness within the speed limit. This provided practical information regarding ultra precision machining.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.416-421
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• 2003

To obtain the surface roughness with range from l0nm to In n need a ultra-Precision machine, cutting condition and the study of materials. And n have to also consider the chip and vibration of diamond tool during processing. In this paper, the cutting conditions for getting mirror surface of aluminum alloy have been examined experimentally by using ultra-precision turning and single crystal diamond tool. In generally, the cutting conditions have effect on the surface roughness in ultra-precision turning. The result of surface roughness was measured by the ZYGO New View 200.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.5
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• pp.64-69
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• 2014

This article presents machining experiments to assess the relationship between the profile accuracy and the workpiece hardness using a natural diamond tool on an ultra-precision diamond turning machine. The study is intended to secure a corner cube prism pattern for reflective film capable of high-quality outcomes. The optical performance levels and edge images of corner cubes having various hardness levels of the copper-coated layer on a carbon steel plate are analyzed. The hardness of the workpiece has a considerable effect on the profile accuracy. The higher the hardness of the workpiece, the better the profile accuracy and the worse the edge wear of the diamond tool.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.897-900
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• 2002

The collimation mirror will be used for thermal vacuum testing of spacecraft. The reflection mirror system to generate parallel beam inside the thermal vacuum chamber. A 600mm diameter aspheric Collimation mirror was fabricated by ultra-precision single point diamond turning (SPDT). Aluminum alloy for mirror substrates is known to be easily machining, but not polishable due to its ductility. Aspheric large collimation reflector without a conventional polishing process, the surface roughness of 10nmRa, and the from error of $\lambda/2 ~\lambda/4(\lambda$ =632.8 nm) for reference curved surface 600 mm has been required. The purpose of this research is to find the optimum machining conditions for reflector cutting of A16061-T651 and apply the SPDT technique to the manufacturing of ultra precision optical components of metal aspheric reflector.

• The Bulletin of The Korean Astronomical Society
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• v.39 no.2
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• pp.109.1-109.1
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• 2014

다이아몬드 선삭 기계(DTM)를 이용한 렌즈 및 반사경 가공은 제작시간 단축 및 비용 절감의 장점을 가지고 있다. 그러나 알루미늄과 같은 무른 금속을 가공하여 반사경을 제작하는 경우에는 반사경 표면에 가공오차가 발생한다. 오차는 크기에 따라 고주파 오차(High Frequency Error, HFE), 중주파 오차(Mid Frequency Error, MFE), 저주파 오차(Low Frequency Error, LFE)로 분류 할 수 있다. LFE는 가공한 반사경 표면이 설계된 형상과 얼마나 다른지를 표현하는 값으로 광학 수차와 같이 해상도를 저하시킨다. MFE는 반사경 표면에 수십 마이크로미터 크기로 나타난다. 회전하는 반사경 시료에 다이아몬드 툴의 홈이 동심원으로 생기면서 회절격자와 같이 회절 및 간섭 현상을 만든다. HFE는 표면의 거친 정도를 나타내며 반사율과 관련되고 수 나노미터 크기로 나타난다. 본 연구에서는 광학 레이저를 사용하여 MFE가 광학 성능에 미치는 영향을 분석하였다. 유리 반사경과 MFE를 제거한 반사경, 제거하지 않은 반사경에 대하여 실험을 진행하였다. 본 실험 결과는 반사경 가공 표면을 평가할 수 있는 유용한 자료가 될 것이다.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.55-60
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• 1994

최근의 사무기기용 다면체반사경을 비롯하여 메모리 디스크,복사기용 드럼등은 물론 레이저 응용, X-선용의 천체망원경 및 현미경등의 광기술에 "초정밀 가공기술"의 용도가 점차 확대되어 가고 있는데, 이는 진보된 과학과 공업기술에 대한 시스템에 있어서 광학, 전기 및 전자 그리고 기계 부품의 생산에 가장 중요한 핵심기술의 하나이다. 본 연구에서는 초정밀 전용 공작기계가 아닌 범용 CNC 선반에 초정밀 절삭공구인 직선 절인의 천연다이아몬드 공구와 공작물로써 알루미늄합금을 장착하고, 선삭하여 초정밀 절삭에 관한 정성적인 데이터를 얻고자, 절삭조건에 따른 표면거칠와 절삭력 등의 변화를 조사하였다.변화를 조사하였다.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.05a
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• pp.265-265
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• 2004

최근 IT산업으로 대표되는 광통신 및 광신호 전달에 이용되는 광 반사경 및 렌즈어레이, 광가이드 판넬(BLU, FLU)등 광부품의 수요가 급증하고 있고, 이의 생산을 위한 다양한 제조공정이 연구 개발되고 있다 근년까지 이러한 마이크로 광부품의 제조방법은 포토리소그래피, 에칭기술을 베이스로 한 MEMS 기술, PDMS를 이용한 복재기술에 크게 의존하고 있다. 기계적 가공법으로는 오래전부터 초정밀 경면 선삭이나 연삭에 의한 마이크로 렌즈와 미세 패턴의 금형가공이 이루어져 왔다.(중략)

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.69-74
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• 2012

Surface roughness is widely used as an index for processing degree of accuracy. Recently, regression analysis to predict the machining results are actively used to characterize a cutting operations. In the past, diamond machining had been used for ultra precision cutting operation, but now industrial diamond tools like PCD(Polycrystalline Diamond) have been widely used in ultraprecision machining of nonferrous metals. In this study, the authors focus on the effect of PCD tool property on the surface roughness of Al5083 aluminum alloy after cutting process by CNC operated lathe. Based on the regression analysis approach on a surface roughness data obtained by experiment, predictive analysis of surface roughness is effective to achieve better surface quality.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.10
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• pp.7-12
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• 2007