• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.1
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• pp.139-144
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• 1991

Chip flow angle is one of the important factors to be determined for the scheme of Chip Control. Up to now, however, a dependable way to predict the chip flow angle in practical cutting has not been established satisfactorily. In this paper a rather simple theoretical prediction of chip flow angle is tried based on some already widely confirmed hypotheses. The developed equation of chip flow angle contains the parameters of depth of cut d, feed rate f, nose radius $r_{n}$ side cutting edge angle $C_{s}$, side rake angle .alpha.$_{s}$ and back rake angle .alpha.$_{b}$. Theoretical results of chip flow angle given by this study bas been shown in a good agreement with experimental ones.s.s.s.s.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.1059-1062
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• 1995

In cutting system, relative displacement between rool and workpiece is very important. Even though there have been so many works for modeling cutting process of end-milling, most of them have considered only one displacement of either tool or workpiece instead of both. In this paper, the relative displacement between tool and workpiece is considered for modeling cutting process of end-milling using simple experimental modal analysis and cutting force simulation program is developed. In cutting force model, instantaneous uncut chip thickness model is used and Runge-Kutta method is used for the simulation of time varying cutting system.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.2
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• pp.73-80
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• 2006

This paper describes a analysis on the chip thickness model required for cutting force simulation in ball-end milling. In milling, cutting forces are obtained by multiplying chip area to specific cutting forces in each cutting instance. Specific cutting forces are one of the important factors for cutting force predication and have unique value according to workpiece materials. Chip area in two dimensional cutting is simply calculated using depth of cut and feed, but not simply obtained in three dimensional cutting such as milling due to complex cutting mechanics. In ball-end milling, machining is almost performed in the ball part of the cutter and tool radius is varied along contact point of the cutter and workpiece. In result, the cutting speed and the effective helix angle are changed according to length from the tool tip. In this study, for chip thickness model analysis, tool and chip geometry are analyzed and then the definition of chip thickness and estimation method are described. The resulted of analysis are verified by compared with geometrical simulation and other research. The proposed chip thickness model is more precise.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.4
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• pp.7-12
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• 2012

The cutting force for peripheral end-milling considering run-out property was estimated and its result was compared with that of measured one. An experimental coefficient modelling was used for the formulation of theoretical end-milling force by considering the specific cutting force coefficient. Also, the specific cutting force, that is the multiplication of specific cutting force coefficient and uncut chip thickness, was used for the prediction of end-milling force. The end-milling force mechanics with run-out was presented for the estimation of theoretical force in peripheral end-milling by considering the geometric shape of the workpiece part. As a result, the estimated end-milling force shows a good consistency with the measured one. And it can be used for the prediction of force history in end-milling with run-out which incurs different start and exit immersion angle in entering and exiting condition.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.7
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• pp.143-148
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• 2001

In this study, a mechanistic model of cutting force components in up and down end milling process is presented. Using this cutting force model of 4-tooth endmills with various helix angles, cutting force variation of inconel 718 has been predicted. Predicted values of cutting force components are coincide well with the measured ones. As helix angle increases, overlapping effects of the active cutting edges increase. In up endmilling the magnitudes of radial and feed cutting force componts FX and FY are lowest when the helix angle is $40\{\circ}$, but in down endmilling the magnitudes of these values increase slightly as helix angle becomes large.

• Composites Research
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• v.24 no.4
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• pp.23-28
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• 2011

Recently CFRP laminate joints process by bolts and nets are developed rapidly in aircraft industries. However, there are serious drawback during jointing process. Many hole processes are needed for the manufacturing and structural applications using composite materials. Generally, very durable polycrystalline crystalline diamond (PCD) drill has been used for the CFRP hole process. However, due to the expensive price and slow process speed, chemical vapor deposition (CVD) diamond drill has been used increasingly which are relatively-low durability but easily-adjustable process speed via drill shape change and price is much lower. In this study, the comparison of hole process between PCD and CVD diamond coated drills was done. First of all, CFRP hole processbility was evaluated using the equations of hole processing conditions (feed amount per blade, feed speed). The comparison on thermal damage occurring from the CFRP specimen was also studied during drilling process. Empirical equation was made from the temperature photo profile being taken during hole process by infrared thermal camera. In addition, hole processability was compared by checking hole inside condition upon chip exhausting state for two drills. Generally, although the PCD can exhibit better hole processability, hole processing speed of CVD diamond drill exhibited faster than PCD case.