• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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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.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1995.10a
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• pp.68-75
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• 1995

The milling process is one of the most important metal removal processes in industry. Due to the complexities inherent to the cutter insert geometry and the milling cutter kinematics, these processes leave an analytically difficult to predict texture on the machined surface's hills and valleys. The instantaneous uncut chip cross sectional area may be estimated by the relative position between the workpiece and the cutter inserts. furthermore, since the cutting forces are proportional to the instantaneous uncut chip cross sectional area, the cutting forces in face milling operations can not be estimated easily. A new simulation program which is based upon the numerical method has been proposed to estimate the cutting force components, with the ability to predict the machined surface texture left by the face milling operation.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2004.11a
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• pp.1056-1061
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• 2004

The vibration of rotor systems is caused by various factors, such as misalignment, unbalance, gear meshing, error of assembly, etc. Modal test and TDA/ODS analysis were done. The dynamic analysis of the armature was done with SAMCEF which is a commercial software for finite element and kinematic analysis. The transient response of the armature is calculated by the SAMCEF with the consideration of magnetic force and bearing stiffness, which are the essential elements for the design of high speed cutter. Main frequency of the vibration is due to the unbalance of the armature. The FEM analysis model considering unbalance and the high speed cutter have same vibration properties. The vibration sources of the high speed cutter is proved to be unbalance.

• Journal of Korean Tunnelling and Underground Space Association
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• v.15 no.3
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• pp.225-235
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• 2013

Cutter forces acting on a disc cutter in TBM are the key parameters for TBM design and its performance prediction. This study aimed to experimentally evaluate cutter forces with different ring shapes in a hard rock. The stiffness of a cutter ring was indirectly estimated from a series of full-scale linear cutting tests. From the experiments, it was verified that the rolling stress acting on a V-shape disc cutter was much higher than on a CCS disc cutter even though the penetration depth by a V-shape disc cutter could be increased in the same cutting condition. Finally, it is suggested that a prediction model considering the shape parameters of a disc cutter should be used for its better prediction.

• Journal of Korean Tunnelling and Underground Space Association
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• v.15 no.3
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• pp.237-251
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• 2013

This study aimed to estimate the axial stress and torque on a shaft in a disc cutter. The corresponding inner temperature and the surface temperature of a cutter ring were also measured by using strain gauges and thermocouples during the linear cutting tests. The maximum values of the axial stress and torque were recorded to 11.3 MPa, $171kN{\cdot}m$ respectively. They have higher correlations with normal force rather than rolling force. The results of temperature measured by thermocouples during a linear cutting test showed that the rate of increase in temperature was below $0.2^{\circ}C$. When the cutter spacing is set to be 70 mm, the inner temperature and surface temperature of a disc cutter were $0.1^{\circ}C/m$, $0.15{\sim}0.17^{\circ}C/m$ respectively. Similarly, when the cutter spacing is 90 mm, the temperature values were $0.09^{\circ}C/m$, $0.13{\sim}0.23^{\circ}C/m$ respectively.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.19-20
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• 2006

As the Mobile and Display technology are being developed quickly, new wireless devices are released in great numbers. They reduce existing devices' life time and demand a reduction of developing period of portable devices. With these demands, existing film cutting mold used many films of portable devices, especially LCD Display, needs to be more precise, and cheaper. In this research, we have analyzed machining characteristics of cutter shapes, materials, and cutting conditions for application to other films. Cutter edge was machined by slot cutting method and CAD program to select the cutter shape and cutter angle. Also, we have determined the optimal cutting conditions using high speed machining experiments to improve the productivity.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.10
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• pp.35-44
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• 1999

The performance of interrupted cutting operations like milling is consideraly affected by cuter runout. In this study, cutter runout is selected as an important machining parameter for evaluation of machinability in ball-end milling and caused from misalignments of tool and holder, unbalanced mass of parts and tool deflection under machining. To evaluate the machinability due to cutter runout, the rotating accuracy of spindle, cutting force and surface roughness are measured. The rotating characteristics of spindle in each revolution speed were investigated by cutter runout in freeload. The predicted surface form of workpiece by measuring cutter runout data was compared with real surfaces. The results show that measuring runout with high response gap sensor is useful for studying the phenomenon of high-speed machining and the monitor surface form using in-process runout measurements in ball-end milling is possible.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.171-178
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• 2000

In this study, an indirect method to estimate the setup runout of a ball-end mill from cutting force signal is proposed. This runout makes cutting forces of each tooth of the milling cutter unequal. By transforming the cutting force model from time domain to frequency domain through time-convolution theorem, the magnitude and phase angle of runout can be explicitly expressed with material constants, cutting conditions, and force signal. The static setup runout can be obtained by extrapolating estimated effective runout, which is independent of feedrate but decreases linearly with increase in axial depth of cut. The setup runout estimated by slot cutting experiments, shows good agreement with the measured one.

• Journal of Korean Tunnelling and Underground Space Association
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• v.16 no.6
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• pp.533-542
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• 2014

In this study TBM disc cutter prediction models including Gehring, CSM and NTNU models were investigated and the characteristics of the models were examined. The influence of penetration, uniaxial compressive strength and abrasiveness index on the models was analyzed. The life of disc cutter linearly increases with penetration per revolution and decreases with increasing uniaxial compressive strength of rocks. As the abrasiveness index, CAI, increases, the life of disc cutter in Gehring and CSM model decreases. On the contrary, the life of disc cutter life in NTNU model decreases with increasing CLI. Also, comparisons of predicted disc life were made between models using actual job site data.

• Journal of Computational Design and Engineering
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• v.3 no.2
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• pp.151-160
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• 2016

Cutter-workpiece engagement (CWE) is the instantaneous contact geometry between the cutter and the in-process workpiece during machining. It plays an important role in machining process simulation and directly affects the calculation of the predicted cutting forces and torques. The difficulty and challenge of CWE determination come from the complexity due to the changing geometry of in-process workpiece and the curved tool path of cutter movement, especially for multi-axis milling. This paper presents a new method to determine the CWE for general milling processes. To fulfill the requirement of generality, which means for any cutter type, any in-process workpiece shape, and any tool path even with self-intersections, all the associated geometries are to be modeled as triangle meshes. The involved triangle-to-triangle intersection calculations are carried out by an effective method in order to realize the multiple subtraction Boolean operations between the tool and the workpiece mesh models and to determine the CWE. The presented method has been validated by a series of case studies of increasing machining complexity to demonstrate its applicability to general milling processes.