• Journal of the Korean Society for Precision Engineering
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• v.20 no.5
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• pp.148-155
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• 2003

Most manufacturing processes such as welding, cutting and molding generate residual stresses on the surface of manufactured parts. Between compressive and tensile residual stresses, the tensile residual stress is harmful to the surface integrity, which results in reduced fatigue life and causes other structural failures when the service stresses are superimposed on the residual stresses. In the research, the residual stresses in the hardened tool steel (SKD11) were measured using hole-drilling method. The specimens were prepared through hard turning. Most of residual stresses in the machined surface were compressive.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.363-366
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• 2003

The hard turning is a turning operation performed in high strength alloy steels (HRC>30) in order to reach surface roughness close to those obtained in grinding. This is possible because of availability of improved tool materials (polycrystalline cubic boron nitride. PCBN), ad more rigid machine tools. According to many previous work of hard turning mechanism, the maximum temperature of cutting can be raised up to 100$0^{\circ}C$. As the heat generation rate is very high, the thermal displacement of tool holder cannot be negligible. Therefore, the aim of this paper is to analyze effects of high heat generation at CBN tool tip to the thermal displacement of a tool holder in hard turning and finally geometric accuracy. The thermal behavior of a CBN tool holder is investigated by numerical simulation and experiment, and the result shows thermal elongation of microns order is possible during hard turning process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1768-1771
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• 2003

Hard turning replaces grinding for finishing process with expectations of higher productivity and demanded surface quality. Especially for the surface roughness as surface quality demanded in finishing process of hard turning, know-how of machining characteristics of hardened materials by cutting force analysis should be accumulated in company with achievement of precision of elements and high stiffness design technology in hard turning. Considering chip formation mechanism of hardened materials, adequate cutting conditions are selected for machining experiments and cutting forces are measured according to cutting conditions. Increase of cutting forces especially thrust force and increase of dynamic instability could occur in hard turning. Analysis of dynamic characteristics of the cutting forces is executed to investigate relation between dynamic instability and surface roughness in hard turning. Investigation on effects of relative motion of machining system generated by vibration due to dynamic instability shows that ultimate surface roughness could be predicted considering relative motion of machining system with geometrical surface roughness.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.9
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• pp.799-804
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• 2014

Hard turning is a machining process for hardened materials with high surface quality so that grinding process can be eliminated. Therefore, the hard turning is capable of reducing machining time and improving productivity. In this study, hardened AISI4140 (high-carbon chromium steel) that has excellent yield strength, toughness and wear resistance was finish turned using CBN tools. Wear characteristics of CBN tool was analyzed in dry and MQL mixed with nano-particle (Nano-MQL). The dominant fracture mechanism of CBN tool is diffusion and dissolution wear on the rake surface resulting in thinner cutting edge. Abrasive wear by hard inclusion in AISI4140 was dominant on the flank surface. Nano-MQL reduced tool wear comparing with the dry machining but chip evacuation should be considered. A cryogenically treated tool showed promising result in tool wear.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.12
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• pp.47-54
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• 2008

Hard turning process can be defined as a single-point machining process carried out on "hard" materials. The process is intended to replace or limit traditional grinding operations that are expensive, environmentally unfriendly, and inflexible. The purpose of this study is to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, tool wear shape and chip formation by the outer cutting of a kind of wear resistant tungsten carbide V30. Hard turning experiments were carried out on this alloy using the PCD (Poly Crystalline Diamond), cBN (cubic Boron Nitride) and PcBN (Polycrystalline cubic Boron Nitride) cutting tools. The PcBN and the usual cBN tools were used to be compare with the PCD tool and the dry turning was carried out. The PcBN is attractive as the tool material which replaces the PCD. The tool wear width and cutting force were measured, and the worn tool and chip were observed. The difference of the tool wear mechanism among the three tool materials was investigated.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.1
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• pp.70-78
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• 2004

This paper presents study of efficiency of wavelet transformation for on-line chatter detection during hard fuming process. From comparison with other time series and statistical methods such as fast fourier transformation (FFT), Kurtosis and standard deviation (STD), wavelet transform is better than others in on-line chatter detection. With using wavelet function with pseudo frequency corresponding to chatter frequency, chatter could be detected more sensitively. And for both force signal from dynamometer and displacement signal from capacitance type cylindrical sensor (CCS), wavelet transform with DB2 function on level 4 could be well used for chatter detection in hard turning process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.1048-1051
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• 2001

This paper presents an analytical and experimental study of a cryogenic machining for precision hard turning. A cryogenic circulation system is designed and mounted on the top of the tool insert. The machining process used is facing operation on a CNC turning center with dry and cryogenic conditions. The tool temperature and cutting forces are measured by the K-type thermocouple and by a three-component Kistler dynamometer, respectively. Both data are fed into the data acquisition program through an A/D card. Surface roughness and form accuracy of the machined surface are measured by WYKO NT2000. It is also found that surface roughness and form accuracy with cryogenic cooling are better than those with no coolant.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.270-276
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• 2000

Hard turning has the potential to replace grinding process and to achieve significant reduction in production time and cost. The main applications for hard turning is finishing process, namely grinding process. Therefore, it must be able to satisfy high surface integrity of the workpiece. This paper discusses surface quality in terms of residual stress and damaged layer with respect to cutting parameters in an intermittent hard turning. Damaged layer experiment is carried out orthogonal array. From that is based on the orthogonal array. From the response table, cutting parameters are analyzed from the view point of the damaged layer and residual stress. From this experimental results, even though in the intermittent hard turning, surface integrity turns out be good enough for replacing grinding process.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2015.11a
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• pp.283-283
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• 2015

현재 LAC 베어링에 적용되는 표면 처리는 일반적으로 하드터닝+슈퍼피니싱 가공이 적용되고 있고, 장수명을 위한 표면 처리 기술이 보다 더 요구되는 추세이다. Burnishing 기술은 매끄럽고 단단한 공구를 베어링 궤도면에 충분한 압력을 가하여 서로 문질러(rubbing) 마찰면을 소성 변형시켜 표면 거칠기 및 압축 잔류 응력 등을 향상 시키는 기술이며, 베어링과 같은 금속의 경우 버니싱 가공 적용 시 광택을 띠는 특성을 가지므로 외관 품질 향상에 기여하므로 슈퍼 피니싱 공정을 대신할 수 있다. 또한 표면 finishing, 표면 경도, 내마모성 및 피로/부식 저항성을 향상시킨다. 이에 본 연구에서는 슈퍼 피니싱 가공을 대신하기 위한 버니싱 가공의 물성을 검토하였고, 다른 공정과의 비교를 통한 버니싱 기술의 효과 확인하였다.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.2
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• pp.147-155
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• 2012

Wind power, which is one of the promising renewable energies, has shown the high growth rate of 35 % of the annual average in the recent 5 years and also windmill related equipment market has been fast-growing. Yaw & Pitch bearing are the key parts of windmill and are machined by huge vertical lathe which is monopolized by the advanced countries. The purpose of this study is to develop the multi-tasking vertical lathe for 5 MW grade windmill bearings, which might be mass produced 3 or 5 years later. In this study, the structure of the crossrail and rotary table, which are the key units of the huge multi-tasking vertical lathe, were optimized through the finite element analysis. Also the basic performance of the rotary table has been evaluated.