• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.2 s.233
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• pp.333-340
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• 2005

Feedrate is one of the factors that have the significant effects on the productivity, qualify and tool life in the cutting mechanism as well as cutting velocity, depth of cut and width of cut. In this study, in order to realize the high-efficient machining, a new feedrate optimization method is proposed based on the concept that the optimum feedrate can be derived from the allowable cutting power since the cutting power can be predicted from the cutting parameters as feedrate, depth of cut, width of cut, chip thickness, engagement angle, rake angle, specific cutting force and so on. Tool paths are extracted from the original NC program via the reverse post-processing process and converted into the infinitesimal tool paths via the interpolation process. And the novel NC program is reconstructed by optimizing the feedrate of infinitesimal tool paths. Especially, the fast feedrate optimization is realized by using the Boolean operation based on the Goldfeather CSG rendering algorithm, and the simulation results reveal the availability of the proposed optimization method dramatically reducing the cutting time and/or the optimization time. As a result, the proposed optimization method will go far toward improving the productivity and qualify.

• Journal of Power System Engineering
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• v.12 no.3
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• pp.66-71
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• 2008

Diamond-like-carbon (DLC) coatings could be good candidates as solid lubricants for cutting tools in dry machining of aluminum alloy. In this work, DLC thin films were produced as a friction reduction coating for WC-Co insert tip using the plasma immersion ion beam deposition (PIIED) technique. DLC coatings were also coated on $Al_2O_3$ specimens and high temperature wear tested up to $400^{\circ}C$ in dry air to observe the survivability of the DLC coating in simulated severe cutting conditions using a pin-on-disc tribotester with Hertzian contact stress of 1.3GPa. It showed reduced friction coefficients of minimum 0.02 up to $400^{\circ}C$. And cutting performance of DLC coated WC-Co insert tips to Al 6061 alloy were conducted in a high speed machining center. The main problems of built-up edge formation in aluminum machining are drastically reduced with improved surface roughness. The improvements were mainly related to the low friction coefficient of DLC to Al alloy and the anti-adhesion of Al alloy to WE due to the inertness of DLC.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.2
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• pp.223-231
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• 1986

During the past decade, the Quick Tool-Life Testing Method has been studied. However, a generalized theory and testing method for the quantitative measurement of tool wear have not been developed yet. Among many factors to affect the tool wear, the flank wear is regarded as a main factor. In this study, the behavior of the flank wear for carbide tool was studied as a preceding step to present a simple method for Quick Tool-Life Testing, and it was found that the flank wear varies in direct proportion to cutting time, and the following general equation is obtained for the flank wear curves with respect to cutting time and velociety.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.6
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• pp.41-46
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• 2017

Productivity improvement and cost reduction in the aircraft industry have become major industrial objectives, and improving productivity by reducing machining time has become a key focus. When numerical cutting code is created by CAM software, such as CATIA or UG-NX, it is impossible to control machining feed speed using cutting force changes depending on the machining tool path. However, machining an aircraft engine part from difficult material, such as Inconel 718, takes a long time, and tool chipping or breakage often occurs from forcing the machining path too quickly. This study investigated and verified the reliability of the AdvantEdge production module (PM)using cutting power tests. In particular, diffuser and diffuser case parts were considered, comparing cutting power and machining time using AdvantEdge PM and CATIA.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.1 s.94
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• pp.219-225
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• 1999

Monitoring of the cutting force signals in cutting process has been well emphasized in machine tool communities. Although the cutting force can be directly measured by a tool dynamometer, this method is not always feasible because of high cost and limitations in setup. In this paper an indirect cutting force monitoring system is developed so that the cutting force in turning process is estimated based on a AC spindle drive model. This monitoring system considers the cutting force as a disturbance input to the spindle drive and estimates the cutting force based on the inverse dynamic model. The inverse dynamic model represents the dynamic relation between the cutting force, the motor torque and the motor power. The proposed monitoring system is realized on a CNC lathe and its estimation performance is evaluated experimentally.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.5
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• pp.631-636
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• 2010

SNCM420 steel is one of the cam shaft materials which are used in the supply unit for ship engine cam shaft. In this study the assessment of cutting behavior was conducted for the SNCM 420 steel and SM45C steel with various cutting conditions as depth of cut 0.5, 1.0, 1.5, 2.0mm and feed rate 0.1~0.3m/rev. The controlled chip was produced in feed rate 0.2, depth of cut 1.0 for SNCM420 and feed rate 0.2, depth of cut 2.0 for SM45C. There is no difference cutting force between SM45C and SNCM420 steels.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.5
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• pp.173-179
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• 2000

While a cutting tool is machining a workpiece at various cutting depth, the feedrate is usually selected based on the maximum depth of cut. Even if this selection can avoid power saturation or tool breakage, it is very conservative compared to the capacity of the machine tools and can reduce the productivity significantly. Many adaptive control techniques that can adjust the feedrate to maintain the constant cutting force have been reported. However, these controllers are not very widely used in manufacturing industry because of the limitations in measuring the cutting force signals. In this paper, turning force control systems based on the estimated cutting force signals are proposed. A synthesized cutting force monitor is introduced to estimate the cutting force as accurately as a dynamometer does. Three control strategies of PI, adaptive and fuzzy logic controllers are applied to investigate the feasibility of utilizing the estimated cutting force fur turning force control. The experimental results demonstrate that the proposed systems can be easily realized in CNC lathe with requiring little additional hardware.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.6
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• pp.799-804
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• 2011

CFRP(Carbon Fiber Reinforced Plastics) has been used many industries aerospace, automobile, medical device and building material industries, etc. Because it is lighter than other metals and has good properties, such as rigidity, strength and wear. CFRP may be cured integrity. However, it needs postprocessing similar to drilling or endmilling for shape cutting and combination of various material. In this paper, tool dynamometer and accelerometer used to signal analysis for machining properties under various cutting conditions and tool shape changes. In addition, microscope used to verify the machined CFRP surface. As the results, it was found that the cutting force and the vibration were decreased in the increasing of cutting edge (2-flute < 4-flute < composite tool), and the good machined surface can be obtained in this experiments.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.4
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• pp.13-19
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• 2012

There are many dynamic properties in measured end-milling force. So, it is difficult to predict the real static property of end-milling force. Also the behavior of end-milling force is very complex to predict with the measured one. To extract the static property from measured force, it must be filtered and its problem is closely related to a de-noising one. Also this paper presents alternative de-noising method of end-milling force using wavelet filter bank, based on the wavelet transform and its inverse one. In this paper, by comparing the measured force and its wavelet filtered one, the fundamental end-milling force property after wavelet transform is well reviewed and analyzed. This result of wavelet filtering with filter bank shows the static force of end-milling which has severe dynamic properties occurring in entry and exit state of edge emersion into the workpiece.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.4
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• pp.381-387
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• 2009

The end-milling force behaviour is very complex and it is related to a de-noising phenomenon, so it is very difficult to detect and diagnose this static cutting force phenomenon. This paper presents a new method of filtering of end-milling force in end-milling operation using filter bank technique, based on the wavelet transform. In this paper by comparing the history of end-milling force using wavelet filtering the fundamental end-milling property of the wavelet transform is well reviewed and analyzed. This result of wavelet transform using filter bank shows the possible static prediction of end-milling force with severe dynamic properties such as chatter in end-milling operation.