• Journal of the Korean Society for Precision Engineering
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• v.16 no.2 s.95
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• pp.123-129
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• 1999

Ball-end milling process is widely used in the die and mold manufacturing because of suitable one for the machining of free-form surface. During the process, the pencil cutting operation can be adopted before finish cut to eliminate overload in uncut area caused by large diameter of ball-end mill. The ball-end mill cutter for the pencil cutting is easily deflected by cutting force due to the long and thin shape, and the tool deflection in pencil cutting is one of the main reason of the machining errors in a free-form surface. The purpose of this study is to find the characteristics of deflected cutter trajectory by constructing measurement system with eddy-current sensor. It was found that the severe reduction of corner radius produced the overcut during the plane cutting. Up cutting method induced the overcut both plane and slope cutting, but down cutting one induced the undercut. From the experiments, down cutting with upward cutting path can generate the small undercut surface.

• IE interfaces
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• v.9 no.2
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• pp.119-128
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• 1996

A procedure is presented for a 3D-contour machining without cutter interferences. The 3D-contouring machining along a spatial curve is often required for manufacturing trimming and flange dies in motor industries. Input data for the machining contour is a spline curve with polynomial vector equation provided by CATIA system. Points are sampled on the contour curve and line segments and helical curves are approximated from the point data. Cutter interference is checked on the approximated spline and all of interference curves are substituted with interference-free helical curves for a tool path generation. The non-machined curve areas are locally machined by tools with smaller diameters. A tool radius offset is considered for generating NC data to be free with tool size.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.7
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• pp.71-79
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• 2002

A new rapid prototyping process, Variable Lamination Manufacturing using a 4-axis-controlled hotwire cutter and expandable polystyrene foam sheet as a laminating material of the part (VLM-S), has been developed to reduce building time and to improve the surface finish of parts. The objective of this study is to reconstruct the surface of the original 3D CAD model in order to generate mid-slice data using the advancing front technique. The generation of 3D layers by a 4 axis-controlled hot-wire cutter requires a completely different procedure to generate toolpath data unlike the conventional RP CAD systems. The cutting path data for VLM-S are created by VLM-Slicer, which is a special CAD/CAM software with automatic generation of 3D toolpath. For the conventional sheet type system like LOM, the STL file would be sliced into 2D data only. However, because of using the thick layers and a sloping edge with the firstorder approximation between the top and bottom layers, VLM-Slicer requires surface reconstruction, mid-slice, and the toolpath data generation as well as 2D slicing. Surface reconstruction demands the connection between the two neighboring cross-sectional contours using the triangular facets. VLM-S employs thick layers with finite thickness, so that surface reconstruction is necessary to obtain a sloping angle of a side surface and the point data at a half of the sheet thickness. In the process of the toolpath data generation the surface reconstruction algorithm is expected to minimize the error between the ruled surface and the original parts..

• Tunnel and Underground Space
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• v.32 no.4
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• pp.243-253
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• 2022

In this study, the cutting efficiency of TBE (Tunnel Boring Extender) was evaluated by using rotary cutting tester. In the rotary cutting test, a specimen which has a drilled hollow hole at the center was made of rock-like material. The specimen was cut by UDC (undercutting disc cutter) with spiral cutting path to simulate the cutting process of TBE. The cutting forces and specific energy were evaluated under different cutting conditions. The results indicated that the cutter forces of UDC linearly increased with the vertical and radial penetration depths. Among the three directional cutter forces, the normal force is larger than other force components. While the specific energy decreased with the two penetration depths, in particular, it was presumed that the specific energy was minimized at a certain value of the ratio of radial to vertical penetration depth.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.1
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• pp.63-70
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• 2009

Proposed in the paper is an algorithm to generate tool-path for sculptured surface machining. The proposed algorithm computes tool path by slicing offset triangular mesh, which is the CL-surface (Cutter Location surface). Since the offset triangular mesh includes invalid triangles and self-intersections, it is necessary to remove invalid portions. For the efficient removal of the invalid portions, we extended the sweep line algorithm. The extended sweep line algorithm removes invalid portions very efficiently, and it also considers various degeneracy cases including multiple intersections and overlaps. The proposed algorithm has been implemented and tested with various examples.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.9
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• pp.53-61
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• 2000

The manufacture of a marine propeller typically requires long lead time to generate 5-axis tool path. Hence it may take several weeks to manufacture a satisfactory propeller with a general purpose CAD/CAM system. In this research a dedicated 5-axis CAD/CAM system for machining marine propellers has been developed, The system employs various methods to enhance the productivity : interference-free tool path generation employing check vectors and optimum cutter size determinants. In addition an iterative NURBS modeling technique is used to improve the accuracy of the modeled surface and effective cutting conditions are determined and recommended empirically to increase the productivity. The proposed CAD/CAM system has been implemented with C++ and OpenGL graphic library on the Windows system. The system validation and sample results are also given and discussed.

• 제어로봇시스템학회:학술대회논문집
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• 1988.10b
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• pp.901-908
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• 1988

In machining die cavities or mechanical parts, we often encounter the needs to remove a material within a given boundary. Even though this pocket cutting capability has been implemented in many NC packages, most of them can handle convex shaped pockets bounded by curves of limited types and numbers. In this work, a procedure has been developed to machine pockets of a free surface bounded by lines, circular arcs and free curves. Also, the cutter location data is computed directly without using iterative method for better computational efficiency.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.06a
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• pp.51-60
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• 2000

High-speed milling machine is being sold mainly in the market of die and mold industries, because it reduces machining time greatly as proportion to the spindle speed of machine tool. From the experimental milling tests, it has been cleared that the ball end mill is quite suitable for high speed milling and also tool wear reduces in higher speed milling condition. And a new milling concept with ultra high speed over 100, 000 rpm is proposed for solving the various problems such as NC cutter path generation and NC feed conformity etc.

• Journal of Korean Institute of Industrial Engineers
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• v.19 no.3
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• pp.123-137
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• 1993

In this paper, an integrated approach is proposed to generate gouging-free Cartesian tool paths for machining sculptured surfaces from 3D measurement data. The integrated CAD/CAM system consists of two modules : offset surface module an Carteian tool path module. The offset surface module generates an offset surface of an object from its 3D measurement data, using an offsetting method and a surface fitting method. The offsetting is based on the idea that the envelope of an inversed tool generates an offset surface without self-intersection as the center of the inversed tool moves along on the surface of an object. The surface-fitting is the process of constructing a compact representation to model the surface of an object based on a fairly large number of data points. The resulting offset surtace is a composite Bezier surface without self-intersection. When an appropriate tool-approach direction is selected, the tool path module generates the Cartesian tool paths while the deviation of the tool paths from the surface stays within the user-specified tolerance. The tool path module is a two-step process. The first step adaptively subdivides the offset surface into subpatches until the thickness of each subpatch is small enough to satisfy the user-defined tolerance. The second step generates the Cartesian tool paths by calculating the intersection of the slicing planes and the adaptively subdivided subpatches. This tool path generation approach generates the gouging-free Cartesian CL tool paths, and optimizes the cutter movements by minimizing the number of interpolated points.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 1994.04a
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• pp.691-700
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• 1994

Voronoi diagram of a set of geometric entities on a plane such as points, line segments, or arcs is a collection of Voronoi polygons associated with each entity, where Voronoi polygon of an entity is a locus of point which is closer to the associated entity than any other entity. Voronoi diagram is one of the most fundamental geometrical construct and well-known for its theoretical elegance and the wealth of applications. Various geometric problems can be solved with the aid of Voronoi diagram. For example, the maximum tool diameter of a milling cutter for rough cutting in a pocket can be easily found, and the pocketing tool path can be efficiently generated from Voronoi diagram. In PCB design, the design rule checking can be easily done via Voronoi diagram, too. This paper discusses an algorithm to construct Voronoi diagram of a simple polygon which consists of simple curves such as line segments as well as arcs in a plane with O(nlogn) time complexity by employing the divide and conquer scheme.