• Proceedings of the KAIS Fall Conference
• /
• 2004.11a
• /
• pp.90-92
• /
• 2004

본 연구에서는 절삭 가공시 공구가 받는 절삭력과 칩-공구 사이에서 발생하는 절삭 열에 의한 공구의 변형을 예측하였다. 3D CAD를 이용하여 공구를 모델링 하였으며 절삭력과 절삭 열을 하중조건으로 부여하여 유한요소해석을 수행하였다. 하중조건으로 사용한 절삭력과 절삭 열은 절삭이론을 이용한 절삭력 모델을 사용하여 예측하였으며 실험을 통해 모델의 타당성을 검증한 결과이다. 그러므로 본 연구는 어떠한 사전 실험도 없이 절삭조건과 재료 물성치 그리고 공구 형상만을 알면 이에 따른 절삭력성분 및 절삭열 등을 얻을 수 있고, 이를 이용하여 절삭 가공시 공구의 변형을 예측할 수 있다.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2002.04a
• /
• pp.239-244
• /
• 2002

This study shows how the change of helix angle for different helix angle end mill affects machining accuracy. It was verified that cutting forces are remarkably low when endmill has helix angle of different helix angle $25^{\circ}\;, \; 31^{\circ}\; , \; 37^{\circ}$and AE signals have less relationship with the chance of helix angle Moreover, as the number of rotations are increased, the AE signals are increased with the proportion to the number but cutting forces are inversely proportional to the rotation.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 1996.10a
• /
• pp.75-78
• /
• 1996

End Milling is avilable for machining the variable shape of products and has been widely applicated in many industries. To manufacture precise products a surface roughness has to be noticable as a improtant parameter. In end milling the research for tool wear has been insufficient because the tool shape and the cutting geometry are complicated. In this paper the pattern of endmill wear is investigated and the machinability is evaluated. As finding out the characteristics of cutting force and surface roughness the effect of endmill wear on machinability is investigated.

• Proceedings of the KSME Conference
• /
• 2004.11a
• /
• pp.928-933
• /
• 2004

A new approach for modelling and simulation of the cutting forces in end milling processes is presented. In this approach, the cutting forces in end milling are modelled based on a predictive machining theory, in which the machining characteristic factors are predicted from input data of fundamental workpiece material properties, tool geometry and cutting conditions. In the model, each tooth of a end milling cutter is divided into a number of slices along the cutter axis. The cutting action of each of the slices is modelled as an oblique cutting process. For the first slice of each tooth, it is modelled as oblique cutting with end cutting edge effect, whereas the cutting actions of other slices are modelled as oblique cutting without end cutting edge effect. The cutting forces in the oblique cutting processes are predicted using a predictive machining theory. The total cutting forces acting on the cutter is obtained as the sum of the forces at all the cutting slices of all the teeth. A Windows-based simulation system for the cutting forces in end milling is developed using the model. Experimental milling tests have been conducted to verify the simulation system.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.39 no.1
• /
• pp.95-103
• /
• 2015

This paper presents the effects of the tool shape on the geometrical characteristics of flat end-milled side walls. A tool shape is characterized by such parameters as helix angle, number of cutting edges, and diameter. The geometrical characteristics of the side walls are represented by the surface profiles in the feed and axial directions, which are orthogonal to each other. The geometrical defects in each direction are estimated based on the instantaneous apparent cutting areas, which are represented by the interference area between the tool and workpiece and that between the cutting edge and workpiece. It is confirmed that a geometrical defect in the feed direction is formed when the tool leaves the workpiece and the curvature of the tool path changes. Defects in the axial direction are also found in the side walls, except for the defect zone in the feed direction. An up-cut using an end-mill with a steeper helix angle, a greater number of cutting edges, and a smaller diameter are thus found to improve the geometrical accuracy of end-milled side walls.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2000.04a
• /
• pp.3-7
• /
• 2000

In this study, a modified model for prediction of cutting force components in up end milling process is presented. Using this cutting force components of 4-tooth endmils with various helix angles have been predicted. Predicted value of cutting force components are well coincide with the measured ones. As helix angle increases overlapping effects of the active cutting edges increase and as a result the amplitudes of cutting force components decrease and the specific cutting energy consumed also decreases

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2004.10a
• /
• pp.237-240
• /
• 2004

Indexable end mills, which consist of inserts and cutter body, have been widely used in roughing of parts in the mold industry. The geometry and distribution of inserts on cutter body are determined by application. This paper proposes analytical cutting force model for indexable flat end-milling process. Developed cutting force model uses the cutting-condition-independent cutting force coefficients and considers runout, cutter deflection and size effect for the accurate cutting force prediction. Unlike solid type endmill, the tool geometry of indexable endmill is variable according to the axial position due to the geometry and distribution of inserts on the cutter body. Thus, adaptive algorithm that calculates tool geometry data at arbitrary axial position was developed. Then number of flute, angular position of flute, and uncutchip thickness are calculated. Finally, presented model was validated through some experiments with aluminum workpiece.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.11
• /
• pp.163-170
• /
• 1997

End milling experiments are conducted to investigate characteristics of acoustic emission (AE) and cutting force singals due to tool fracture. The AE signals are obtained with a sensor attached to cutting fluid discharge nozzle. Tool states are identified with scanning electron microscopy and optical microscopy. It is demonstrated that the AE signals provide reliable informations about the cutting processes and tool states. Morever, tool fracture can be detected successfully using both the AE count rate and the standard deviation of principal cutting force.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.05a
• /
• pp.907-911
• /
• 2000

In this study, a modified model for prediction of cutting force components in down end milling process is presented. Using this cutting force components of 4-tooth endmills with various helix angles have been predicted. Predicted values of cutting force components are well coincide with the measured ones. As helix angle increases overlapping effects of the active cutting edges increase and as a result the amplitudes of cutting force components decrease.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1995.10a
• /
• pp.161-164
• /
• 1995

Nonlinear analysis of various phenomena has been developed with improvement of computer. The characteristics form nonlinear analysis are available in monitoring and diagnosis state of system. There are many nonlinear property in cutting process, but nonlinear signals have been considered as noise. In this study, nonlinear analysis technique is applied and it will be verified that cutting force is chaos by calculating Lyapunov exponents,fractal dimension and embedding dimension. The relation between characteristic parameter calculated form sensor signal and various cutting condition is investigated.