• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.9
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• pp.761-769
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• 2008

The majority of mechanical parts are manufactured by milling machines. Hence, geometrically efficient algorithms for tool path generation and physical considerations for better machining productivity with guarantee of machining safety are the most important issues in milling tasks. In this paper, an optimized path generation algorithm for direction parallel milling which is commonly used in the roughing stage is presented. First of all, a geometrically efficient tool path generation algorithm using an intersection points-graph is introduced. Although the direction parallel tool path obtained from geometric information have been successful to make desirable shape, it seldom consider physical process concerns like cutting forces and chatters. In order to cope with these problems, an optimized tool path, which maintains constant MRR in order to achieve constant cutting forces and to avoid chatter vibrations at all time, is introduced and the result is verified. Additional tool path segments are appended to the basic tool path by using a pixel based simulation technique. The algorithm has been implemented for two dimensional contiguous end milling operations, and cutting tests are conducted by measuring spindle current, which reflects machining situations, to verify the significance of the proposed method.

• Transactions of Materials Processing
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• v.21 no.5
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• pp.312-318
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• 2012

With an increasing trend toward miniaturization, electrical discharge machining(EDM) has been receiving a lot of attention as a suitable production technology for micro-parts, since it enables the machining of hard conductive materials with a high degree of repeatability and without alteration to the material. When a micro-hole is fabricated by EDM, however, the diameter of the inlet hole is larger than that of the outlet region due to the additional discharge effect caused by the eroded particles. In this paper, a shot blasting surface treatment, in which an abrasive material is accelerated through a pressurized nozzle and directed at the surface of a part, is suggested as an effective method to reduce the tapered shape of EDM micro-hole. In addition, the influence of process parameters such as spark-on time and electrode diameter on the machining performance was investigated. It is shown quantitatively that the difference in diameter between the inlet and outlet holes decreases with the shot blasting treatment and with decreasing spark-on time.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.4
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• pp.20-29
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• 2004

A Tool wear monitoring system is indispensable for better machining productivity with guarantee of machining safety by informing the tool changing time in automated and unmanned CNC machining. Different from monitoring using other signals, the monitoring of spindle current has been used without requiring additional sensors on machine tools. For the reliable tool wear monitoring, current signal only of tool wear should be extracted from other parameters to avoid exhaustive analyses on signals in which all parameters are fused. In this paper, influences of force components of parameters on measured spindle current are investigated and a hybrid approach to cutting force regulation is employed for tool wear signal extraction in the spindle current. Finally, wear levels are verified with experimental results by means of real-time feedrate aspects changed to regulate the force component of tool wear.

• International Journal of Precision Engineering and Manufacturing
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• v.9 no.2
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• pp.54-62
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• 2008

This investigation deals with machining AISI 52100 steel using a carbide-coated tool. The machining cutting force and tool tip temperature are measured online while turning using different cutting parameters. The surface roughness is also measured, but off-line after each cut. The obtained data are analyzed and the influence of the cutting parameters on the machining variables is determined in the form of plots. Regression models obtained from the results are tested using additional experimental data.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.2
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• pp.35-44
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• 2009

Long stroke Fast Tool Servo (LFTS) with maximum stroke of $432{\mu}m$ is designed, manufactured and tested for fabrication of optical free-form surfaces. The large amount of stroke in LFTS has been realized by utilizing the hinge and lever mechanisms which enable the displacement amplification ratio of 4.3. In this mechanism the peculiar shape was devised for maximizing the displacement of end tip in LFTS and special mechanical spring has been mounted to provide the sufficient preload to the piezoelectric actuator. Also, its longitudinal motion of tool tip can be measured by capacitive type displacement sensor and closed-loop controlled to overcome the nonlinear hysteresis. In order to verify the static and dynamic characteristics of designed LFTS, several features including step response, frequency response and cut-off frequency in closed-loop mode were experimentally examined. Also, basic machining result shows that the proposed LFTS is capable of generating the optical free-form surface as an additional axis in diamond turning machine.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.8
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• pp.48-53
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• 2010

5-axis CNC machining now is getting popular because it can deal with complex shapes such as impeller, turbine blade and propeller without additional equipment or process, proving a set of various tool orientations. CAM software related to 5-axis machining is being developed quickly so that users can take advantage of potential capacities of 5-axis machine tools. However, only a few researches can be found in the area of control strategy development for 5-axis machining. This paper proposes a 5-axis cross-coupling control system based on a novel tool orientation error model. The proposed tool orientation error model provides accurate information on the tool orientation error in real time, which in turn enables directly controlling the tool orientation accuracy. The proposed control system also employs a contour error model to calculate the contour error and reflect it in the control as well. The accuracy of the proposed tool orientation error model is verified and the performance of the 5-axis cross-coupling control system in terms of both contouring and tool orientation accuracy is evaluated through computer simulations compared with existing 5-axis control systems.

• International Journal of Precision Engineering and Manufacturing
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• v.8 no.3
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• pp.14-19
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• 2007

Rapid prototyping (RP) technology can fabricate any 3D physical model regardless of geometric complexity using the layered manufacturing (LM) process. Stereolithography (SL) is the best-known example of RP technology. In general, the surface quality of a raw SL-generated part is unsatisfactory for industrial purposes due to the step artefact created by the LM process. Despite of the increased number of applications for SL parts, this side effect limits their uses. In order to improve their surface quality, additional post-machining finishing, such as traditional grinding, is required, but post-machining is time consuming and can reduce the geometric accuracy of a part. Therefore, this study proposes a post-machining technology combining coating and grinding processes to improve the surface quality of SL parts. Paraffin wax and pulp are used as the coating and grinding materials. By grinding the coating wax only up to the boundary of the part, the surface smoothness can be improved without damaging the surface. Finally, moulding and casting experiments were performed to confirm the suitability of the SL parts finished using the proposed process with rapid tooling (RT) techniques.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.1
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• pp.23-31
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• 2006

The present works concerns a side flushing device for the improvement of the conventional Electric-Discharge Machining(EDM) process. In the EDM process, chips are usually generated as the workpiece is removed, and deposited between the electrode and the workpiece. This sediment degrades the surface finish of the machined product as well as the processing efficiency. In the present study, a flushing device with additional side injection equipments is proposed in order to remove the deposited chips effectively. Through numerical simulations, the validity of the proposed device is verified, and the influence of process parameters is investigated. Experiments have been also carried out in the die sinking EDM process. It was observed that the process efficiency and the surface finish are improved by virtue of the proposed flushing device.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.6
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• pp.98-104
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• 1999

As the accuracy of manufactured goods needed high accuracy processing has made the efficiency of NC and measurement technology development, the innovation of machine tools has influence the development of the semi-conductor and optical technology. The movement errors can be expressed in terms of yaw, roll an pitch etc. In the case of expanding the error range, static, dynamic and servo gain errors can be included. Machining center might have twenty-one movement errs including three types of joint errors. Those errors have been measured on the condition of just loading of standard table. Regarding these measuring methods, the mechanical compliance of the structure has not been considered. In this paper, therefor, the influences of the additional load on the positioning accuracy are investigated. The results and the techniques proposed in this study can be considered very effective and useful to compensate more correctly the positioning motion.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.6
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• pp.38-43
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• 2006

A slot cut in end milling processes is one of the laborious works because the cutting force is likely to deflect the tools excessively, then to make large errors or to fracture the tool. This difficulty is owing to the poor stiffness of slender shaped end mills. Though, in most cases, additional finish cuts are followed after rough cuts, the accuracy of rough cuts is still important because it affects the final accuracy after finish cuts and productivity. The accuracy in slot cuts depends on the tool stiffness and the cutting conditions including depth of cut and feed. In order to meet the desired accuracy, diameter of end mill and cutting allowance have to be selected carefully. This study suggests several guidances for selecting the end mill diameter and the slot cut allowance to improve machining accuracy and productivity in slot end millings. Some experiments were done with the various cutting parameters of tool diameter, depth of cut and feed.