• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.381-386
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• 1999

In machining with cutting tool inserts having complex chip groove shape, the flow, curl and breaking patterns of the chip are different than in flat-face type inserts. In the present work, an effort is made to understand the three basic phenomena occurring in a chip since its formation in machining with groove type and pattern type inserts. These are the initial chip flow, the subsequent development of up and side curl and the final chip breaking due to the development of torsional and banding stresses. In this paper, chip flow angle in a groove type and pattern type inserts. The expression for chip flow angle in groove type and pattern type insets is also verified experimentally using high speed filming techniques.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.485-489
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• 2004

Cutting force is important to understand cutting process in milling. To measure cutting force, tool dynamometer is widely used but it is hard to apply in workshop condition. Cutting force measurement which doesn't affect cutting process is needed. Using relations between cutting force and spindle displacement, cutting force can be predicted. Cylindrical capacitive sensor was used to measure spindle displacement during cutting. And signals from tool dynamometer collected to compare with spindle displacement. The result shows spindle displacement has a linear relation with cutting force. Using this result, a simple method to predict cutting force could be applied at workshop condition.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.61-66
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• 1994

Tool condition monitoring is one of the most important aspects to improve productivity and quality and to achieve intelligent machining system. The tool state is classified into three groups as chipping, wear and fracture. In this study, wear of a ceramic cutting tool for hardened die material (SKD11) was investigated. Flank wear was occured more dominant than crarer wear. Therefore, to predict flank wear, the modeling of cutting force has been performed. The modeling of cutting force by an assumption that act the stress distribution on the tool face obtained through a numerical analysis. The relationships between the cutting force and the tool wear can be constructed by machining paraneters with cutting conditions. Experiments were performed under the various cutting conditions to ensure the validity of force models. The theoretical predictions of the flank wear is approximately in good agreement with experimental result.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.4 s.97
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• pp.229-236
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• 1999

The surface, generated by end milling operation, is deteriorated by tool runout, vibration, tool wear and tool deflection, etc. Among them, the effect of tool deflection on surface accuracy is analyzed. Surface generation model for the prediction of the topography of machined srufaces has been developed based on cutting mechanism and cutting tool geometry. This model accounts for not only the ideal geometrical surface, but also the deflection of tool due to cutting force. For the more accurate prediction of cutting force, flexible end mill model is used to simulate cutting process. Computer simulation has shown the feasibility of the surface generation system. Using developed simulation system, the relations between the shape of end mill and cutting conditions are analyzed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.6
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• pp.9-15
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• 2011

Any relative deformation between the cutting tool and the workpiece at machining point results directly in geometric and dimensional errors. The sources of relative deformations between the cutting tool and the workpiece at the contact point may be due to vibration, thermal deformation and cutting forces. In this paper, geometric error prediction of workpiece in turning has been investigated. To reach this goal, turning experiments are carried out according to selected cutting conditions. The variable cutting conditions are cutting speed, depth of cut and feed rate. The results will be useful as a guidance to select cutting conditions to improve the geometrical accuracy.

• 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.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.3
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• pp.114-121
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• 1997

In this paper, the automated initial process planning for 3-axis NC machining of sculptured surfaces is persented. The solution algorithms determining three process planning functions, i.e. machining feasibility, setup orientation and feasible machine selection are developed. The machining feasibility is determined by means of BSM(Binary Spherical Map) which derives its solution quickly in algebraic form, and the setup orientation is determined so that the cutting force is minimized. Finally, the feasible machine is determined by computing the minimum motion ranges of each control axisl. The developed algorithms are tested by numerical simulations, convincing they can by readily implemented on the CAD/CAM system as a process planner.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.6
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• pp.1523-1532
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• 1990

The objective of this study is to develope an optimized multi-facet drill (MFD). The principal factors that affect drilling performance are its geometry and the cutting conditions. In particular, the helix angle in the total twist angle of the twist drill, affects much morgen influence on the dynamic and static stiffness and on determining the characteristics of the chip disposal capacity of the drill. In this study, considering the helix angle as a major parameter, the model was developed. From this model, the deformation of transverse direction was simulated with the bending forces applied. The performance of a drill largely depends upon drilling forces. Comprehensive models for predicating the drilling thrust and torque are developed for the different drill geometries. The effects of MFD geometric parameters on thrust and torque are also deduced from the prediction models, from which an optimal drill geometry is found with the emphasis on minimum drilling forces.

• Journal of Korean Tunnelling and Underground Space Association
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• v.16 no.2
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• pp.237-248
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• 2014

Linear cutting test is known to be very effective to determine machine parameters (i.e. thrust force and torque) and to estimate penetration rate of TBM and other operation conditions. Although the linear cutting test has significant advantages, the test is expensive and time-consuming because it requires large size specimen and high load capacity of the testing machine. Therefore, a few empirical prediction models (e.g. CSM, NTNU and QTBM) alternatively adopt laboratory index tests to estimate design parameters of TBM. This study discusses the estimation method of TBM machine parameters and disc cutter consumption using punch penetration test and Cerchar abrasion test of which the researches are rare. The cutter forces and cutter consumption can be estimated by the empirical models derived from the relationship between laboratory test result with field data and linear cutting test data. In addition, the estimation process was programmed through which the design parameters of TBM (e.g. thrust, torque, penetration rate, and cutter consumption) are automatically estimated using laboratory test results.

• Journal of the Korean Geotechnical Society
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• v.23 no.7
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• pp.57-64
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• 2007

This study proposes a method to estimate drilling torque during ground boring with an aid of electrical energy required for rotating a boring-auger. Ground boring is commonly used in geotechnical engineering such as preboring precast pile installation, soil-cement grouting, ground exploration and so forth. In order to understand the correlation between required electrical energy to rotate the boring auger and the drilling torque, a small laboratory apparatus was designed and a pilot study was performed. The apparatus rotates common drill bits of $D=5{\sim}25mm$ in CBR specimens. The velocity of a bit is 19 RPM and predefined using a reduction gear which connects a main rotation axis to a 25 Watts AC electrical motor shaft. In the middle of drilling the motor current increments and the drilling torque were measured and the correlation between the current and the torque was obtained through linear square fits. Based on the correlation the acquired motor current during drilling was applied to predict the drilling torque in consequent testing and the prediction results were compared to the measured torque. The comparison leads a conclusion that the motor current during drilling using electrical power may be a good indicator to estimate/determine strength characteristics of the ground.