• 한국터널지하공간학회 논문집
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• 제24권6호
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• pp.553-581
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• 2022

TBM (Tunnel Boring Machine)이 터널 산업에 도입된 이후로 안전성과 친환경의 이점으로 TBM의 사용이 전 세계적으로 증가하였다. 암반 및 토사 지반을 굴착하는 TBM 터널에서의 주요 비용 중 하나는 손상되거나 마모된 커터의 교체로 볼 수 있다. 커터의 교체는 시간과 비용에 큰 영향을 끼치는 작업이며 TBM 가동률과 굴진율을 크게 감소시킬 수 있다. 따라서 커터의 수명을 정확하게 평가하는 것은 공기와 비용의 측면에서 매우 중요하다. 그러나 복합 지반을 포함하여 토사 구간, 암반구간에서 커터 마모에 대한 예측은 매우 복잡하고 명확하지 않다. 이에 따라 커터 마모에 대한 다양한 예측 모델이 개발 및 도입되었지만 이러한 불확실성으로 인해 가변적인 결과를 나타낸다. 본 연구에서는 커터 마모 예측 모델을 제시하기 보다는 커터 교체의 설계 및 시공 사례 연구를 소개하고 분석했다. 커터는 지반 조건, TBM 장비 및 운전의 영향을 많이 받으므로 불확실성과 한계를 감안하면 신뢰성 있는 예측 모델을 제안하는 것은 매우 어렵기 때문에 오히려 실제 사례를 분석하고 이에 대한 자료 공유가 더 실용적이다. 커터 교체에 대한 예측과 결과 간의 차이를 확인하고 심도 있게 분석하였다.

• International Journal of CAD/CAM
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• 제3권1_2호
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• pp.1-12
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• 2003

When milling concave corners, cutter load increases momentarily and fluctuates severely due to concentration and uneven distribution of material stock. This abrupt change of cutter load produces undesirable machining results such as wavy machined surface and cutter breakage. An important factor for studying cutter load in 2.5D pocket milling is the instantaneous Radial Depth of Cut (RDC). However, previous work on RDC under different corner-cutting conditions is lacking. In this different corner shapes. In our work, we express RDC mathematically in terms of the instantaneous cutter engage angle which is defined as Cutter Swept Angle (CSA). An analytical approach for modeling CSA is explained. Finally, examples are shown to demonstrate that the proposed CSA modeling method can give an accurate prediction of cutter load pattern at cornering cut.

• 한국기계가공학회지
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• 제16권5호
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• pp.7-12
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• 2017

It is assumed that the buckling and cutting conditions depending on the slenderness ratio will affect the machining quality of the rotary boring tool mounted on a milling machine. In this study, the boring cutter was designed and fabricated to precisely create the Ø30 hole. Through the performance evaluation, the accuracy of the hole according to the slenderness ratio and cutting conditions was analyzed, and the following conclusions were obtained. The higher the RPM, the smaller the change in the working diameter, and the smaller the hole. Next, the smaller the slenderness ratio, the smaller the change in straightness due to the change in cutting conditions. Finally, the slenderness ratio also affects the tendency for changes in the concentricity. The larger the slenderness ratio, the more sensitive the concentricity to changes in cutting conditions.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1995년도 추계학술대회 논문집
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• pp.151-156
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• 1995

This paper presents a methodology for real-time detecting and identifying the runout geometry of an end mill. Cutter runout is a common but undesirable phenomenon in multi-tooth machining such as end-milling process because it introduces variable chip loading to insert which results in a accelerated tool wear,amplification of force variation and hence enlargement vibration amplitude. Form understanding of chip load change kinematics, the analytical sutting force model was formulated as the angular domain convolution of three dynamic cutting force component functions. By virtue of the convolution integration property, the frequency domain expression of the total cutting forces can be given as the algebraic multiplication of the Fourier transforms of the local cutting forces and the chip width density of the cutter. Experimental study are presented to validata the analytical model. This study provides the in-process monitoring and compensation of dynamic cutter runout to improve machining tolerance tolerance and surface quality for industriql application.

• 한국생산제조학회지
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• 제7권2호
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• pp.91-99
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• 1998

This paper presents a methodology for identifying the cutter runout geometry in end milling process. Cutter runout is common but undesirable phenomenon in multi-tooth machining because it introduces variable chip loading to insert which results in a accelerated tool wear. amplification of force variation and hence enlargement vibration amplitude From understanding of chip load change kinematics, the analytical cutting force convolution model was formulated as the angular domain convolution model was formulated as the angular domain convolution of three dynamic cutting force component functions. By virtue of the convolution integration property, the frequency domain expression of the local cutting forces and the chip width density of the cutter. Experimental study is presented to validate the analytical model. This study provides the in-process monitoring and compensation of dynamic cutter runout to improve machining tolerance and surface quality for industrial application.

• 한국정밀공학회지
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• 제15권5호
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• pp.65-71
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• 1998

This paper presents in-process compensation methodology to eliminate cutter runout and improve machined surface quality. The cutter runout compensation system consists of the micro-positioning mechanism with the PZT (piezo-electric translator) which is embeded in the sliding table to manipulate the radial depth of cut in real time. For the implementation of cutter runout compensation methodology. cutting force adaptive control was proposed in the angle domain based upon PI (proportional-integral) control strategy to eliminate chip-load change in end milling process. Micro-positioning control due to adaptive acuation force response improves the machined surface quality by compensation or elimination of cutter runout induced cutting force variation. This results will provide lots of information to build-up the precision machining technology.

• 한국지반공학회:학술대회논문집
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• 한국지반공학회 2010년도 춘계 학술발표회
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• pp.562-570
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• 2010

This study was conducted to estimate the number of disc cutter consumption and to predict amount of disc cutters when a shield TBM(Tunnel Boring Machine) of the Han Riverbed Tunnel was applied. In fact, it is almost impossible to change the machine after starting the excavation using the shield TBM method. Therefore, it is important to design an appropriate equipment in the shield method - an efficiency choice of the operation equipment plays a key role in the shield tunnel processing. For the above reason, the disc cutter consumption prediction is quite important so that the detailed analysis is required. A number of disc cutter consumption was predicted by the three methods, viz. KOMATSU, MITSUBISHI and NTNU. In addition, the predicted results were compared with field data. The prediction of disc cutter consumption showed that 237 for KOMATSU, 501 for MITSUBISHI, and 634 for NTNU, respectively. However, a total number of 1,263 disc cutter consumption were investigated during the tunnel construction. It was found that there was a huge difference between the predicted and real values of the disc cutter consumption. The more detailed investigation showed that the disc cutter was worn out bluntly in the northbound tunnel, meanwhile it was worn out sharply in the southbound tunnel. In particular, the disc cutter consumption in the southbound tunnel was increased rapidly because of rear abrasion for remaining mucks in the chamber.

• 한국기계가공학회지
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• 제19권6호
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• pp.49-54
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• 2020

The purpose of this study is to investigate the effects of the change in the spindle speed and the feed rate on the diameter change of a hole using a boring cutter for the internal boring process of AL6061-T4 alloys. The experimental results are quantitatively analyzed by applying the factor analysis and the response surface analysis of the experimental design method. The tendency of the diameter change according to the change in the spindle speed and feed level is also evaluated. During the internal boring process of AL6061-T4 alloys, the main factor affecting the diameter change is the spindle speed in which the diameter decreases as the number of revolutions increases. In addition, the diameter tends to increase as the feed is increased; however, as the number of spindle revolutions increases, the influence of the feed decreases.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 추계학술대회 논문집
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• pp.985-988
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• 1997

In end milling process, the undeformed chip section area and cutting forces vary periodically with phase change of the tool. However the real undeformed chip section area deviates from the geometrically ideal one owing to cutter runout and tool shape error. In this study ,a method of estimating the real undeformed chip section area which reflects cutter runout and tool shape error was presented in up end milling process using measured cutting forces. Size effect was identified from the analysis of specific cutting resistance obtained by using the modified undeformed chip section area.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 추계학술대회 논문집
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• pp.1018-1022
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• 2000

Enhancement of the accuracy of products and productivity are essential to survive in a global industrial competition. This trend requires tighter dimensional tolerance specifications. To actively cope with the rapid change of the workpiece material and cutter geometry, a general method that can predict and analyze the machined surface is needed. Surface generation model for the prediction of the topography of machined surfaces is developed based on cutting force model considering cutter deflection and runout. This paper presents the method that constructs the three-dimensional machined surface error following the movement of a cutter, irrespective of the variations of cutting conditions. In addition, the effects of the cutting forces and the kink shape on the machined surface are extensively investigated.