• 한국생산제조학회지
• /
• 제24권2호
• /
• pp.172-176
• /
• 2015

In this research, a tool was developed to automate one-dimensional finite element analysis (1D FEA) for design of a machine tool spindle. Based on object-oriented programing, this tool employs the objects of a CAD system to construct a geometric model and then to convert it into the FE model of 1D beams at the workbenches of the CAD system with minimum data to define the spindle such as bearing positions and cross-sections of the shaft. Graphic user interfaces were developed for users to interact with the tool. This tool is helpful in identifying a near optimal design of the spindle with the automation of the FEA process with numerous design changes in minimum time and efforts. It is also expected to allow even design engineers to perform the FEA in search of an optimal design of the machine tool spindle.

• 한국정밀공학회지
• /
• 제10권4호
• /
• pp.206-215
• /
• 1993

The finite element method is applied to analyze the mechanism of metal cutting, especially micro metal cutting. This paper introduces some effects, such as constitutive deformation laws of workpiece material, friction of tool-chip contact interfaces, tool rake angle and also simulate the cutting process, chip formation and geometry, tool-chip contact, reaction force of tool. Under the usual plane strain assumption, quasi-static analysis were performed with variation of tool-chip interface friction coefficients and tool rake angles. In this analysis, cutting speed, cutting depth set to 8m/sec, 0.02mm, respectively. Some cutting parameters are affected to cutting force, plastic deformation of chip, shear plane angle, chip thickness and tool-chip contact length and reaction forces on tool. Several aspects of the metal cutting process predicted by the finite element analysis provide information about tool shape design and optimal cutting conditions.

• 한국정밀공학회지
• /
• 제28권3호
• /
• pp.363-369
• /
• 2011

In this study, a direct pattern forming process on a plastic film using ultrasonic vibration energy is investigated. A tool horn containing micro-patterns is attached to an ultrasonic power supply, and is used to press a plastic film with ultrasonic vibration in order to replicate micro-patterns on the surface of the plastic film. To replicate micro-patterns with high accuracy, the tool horn should be designed to allow only the longitudinal vibration, not the transverse vibration. For this purpose, the design of a tool horn is investigated through finite element analysis, from which the resulting natural frequency of the tool horn can be adjusted in the range of the ultrasonic power supply. The analysis result is then reflected on the optimal design and fabrication of the tool horn. The validity of the developed tool horn is discussed through pattern-forming experiments using the ultrasonic vibration of the developed tool horn.

• 한국생산제조학회지
• /
• 제19권4호
• /
• pp.498-503
• /
• 2010

The main purpose of this study strongly concerned micro machining error estimation by using FEM analysis of tool deflection shapes in micro flat end-milling process. For the precision micro flat end-milling process, analysis of micro cutting errors is mandatory. In general, tool deflection is a major factor which causes cutting error and limits realization of the high-precision cutting process. Especially, in micro end-milling process, micro tool deflection generates very serious problems in contrast to macro tool deflection. Methods which deal with compensation of cutting error by tool deflection in macro end-milling process have been studied plentifully but, few researches transact with micro scaled cutting tool deflection in micro cutting process. Therefore, the trend of micro tool deflection was estimated by using FEM analysis in this paper. Cutting forces were acquired by micro dynamometer and these were utilized in FEM analysis. In order to verify FEM analysis results, micro machining processes were carried out and real machined profiles were compared with FEM results. Finally through the proposed approach well suited FEM results were obtained.

• 한국생산제조학회지
• /
• 제21권5호
• /
• pp.691-696
• /
• 2012

In this study, a rigid multi-body dynamic model has been developed for mechatronic analysis to evaluate dynamic behavior of a machine tool. The development environment was the commercialized analysis tool, ADAMS, for rigid multi-body dynamic analysis. A simplified servo control logic was implemented in the tool using its functions in order to negate any external tool of control definition. The advantage of the internal implementation includes convenience of the analysis process by saving time and efforts. Application of this development to a machine tool helps to evaluate its dynamic behavior against feeding its component, to calculate the motor torque, and to optimize parameters of the control logic.

• Structural Engineering and Mechanics
• /
• 제31권1호
• /
• pp.57-74
• /
• 2009

Power signals resulting from spindle and feed motor, present a rich content of physical information, the appropriate analysis of which can lead to the clear identification of the nature of the tool wear. The partial least-squares regression (PLSR) method has been established as the tool wear analysis method for this purpose. Firstly, the results of the application of widely used techniques are given and their limitations of prior methods are delineated. Secondly, the application of PLSR is proposed. The singular value theory is used to noise reduction. According to grey relational degree analysis, sample variable is filtered as part sample variable and all sample variables as independent variables for modelling, and the tool wear is taken as dependent variable, thus PLSR model is built up through adapting to several experimental data of tool wear in different milling process. Finally, the prediction value of tool wear is compare with actual value, in order to test whether the model of the tool wear can adopt to new measuring data on the independent variable. In the new different cutting process, milling tool wear was predicted by the methods of PLSR and MLR (Multivariate Linear Regression) as well as BPNN (BP Neural Network) at the same time. Experimental results show that the methods can meet the needs of the engineering and PLSR is more suitable for monitoring tool wear.

• 한국정밀공학회지
• /
• 제16권1호통권94호
• /
• pp.182-190
• /
• 1999

The objective of this study is to develop an analysis scheme in order to predict regrinding due to tool wear in shearing process. The analysis of material now and fracture in shearing process should precede the prediction of tool wear. Thus the developed FE-program to analyze shearing process is used. In order to predict tool wear, the wear model is reformulated as an incremental form and then the wear depth of tool is calculated at each deformation path. Because the regrinding of shearing tool is determined on the basis of allowable size of burr, the analysis of shearing process is iteratively performed using the worn profile of tool. To show the effectiveness of the scheme the simulation result is compared with experimental one.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2003년도 춘계학술대회 논문집
• /
• pp.569-572
• /
• 2003

In VLM-ST process, the fine detailed shape processing process is needed due to the use of thick sheets for layers. The developed process perform the fine detailed shape processing in VLM-ST parts using non-contact hot tool. To predict the heat-affected zone and temperature distribution of VLM-ST parts in detailed shaping, the heat flux from the tool to the surface was calculated for the finite element analysis by modeling the tool as a heat source of radiation. The dominant process parameters such as the radiated heat input, the tool speed, and the gap between the tool tip and the foam sheet (tool height) were considered in the analysis. The results showed a good agreement with the experiments.

• 소성∙가공
• /
• 제10권2호
• /
• pp.144-150
• /
• 2001

Tool design is introduced in a multi-stage rectangular cup drawing process with the large aspect ratio. Finite element simulation is carried out to investigate deformation mechanisms with the initial tool design. The analysis reveals that the difference of the drawing ratio and the irregular contact condition produces non-uniform metal flow to cause wrinkling and severe extension. For remedy, the modification guideline is proposed in the design of the tool and process. Analysis results confirm that the modified tool design not only improves the quality of a deep-drawn product but also reduces the possibility of failure.

• 한국경영과학회:학술대회논문집
• /
• 대한산업공학회/한국경영과학회 1994년도 춘계공동학술대회논문집; 창원대학교; 08월 09일 Apr. 1994
• /
• pp.596-605
• /
• 1994

An efficient measurement and evaluation system for hand tool tasks will provide a practical solution to the problem of designing and evaluating manual tool tasks in the workplace. Few studies on the biomechanical analysis of hand postures and tool handling tasks exist because of the lack of appropriate measurement techniques for hand force. A measurement system for the finger forces and joint angles for analysis of manual tool handling tasks was developed in this study. The measurement system consists of a force sensing glove made from twelve Force Sensitive Resistors and an angle-measuring glove (Cyberglove$\^$TM/, Virtual technologies) with eighteen joint angle sensors. A biomechanical model of the hand using the data from the measurement system was also developed. Systems of computerized procedures were implemented integrating the hand posture measurement system, biomechanical analysis system, and the task analysis system for manual tool handling tasks. The measurement system was useful in providing the hand force data needed for an existing task analysis system used in CTD risk evaluation. It is expected that the hand posture measurement developed in this study will provide an, efficient and cost-effective solution to task analysis of manual tool handling tasks. These tasks are becoming increasingly important areas of occupational health and safety of the country.