• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2002.05a
• /
• pp.980-983
• /
• 2002

In micro-machining, diamond tool is commonly used because it brings much better micro-machinability due to its edge sharpness. However, it is a big question even how thinly the sharp edge of a diamond tool can cut a ship from the workpiece surface. This paper is to investigate the critical cutting depth, at which the dominant cutting mode changes from chip formation to burnishing or vice versa, for a given edge radius. The theoretically critical cutting depth is 0.25$\mu\textrm{m}$(0.8$\mu\textrm{m}$) in cutting using a square type(V-type) diamond tool that has edge radius of 1$\mu\textrm{m}$(1.5$\mu\textrm{m}$). Experimentally, the dominant cutting mode changes and cutting surface becomes better at critical cutting depth. To get high quality surface, depth of cut must be critical cutting depth because less plastically deformed substrate is left on the surface.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2003.04a
• /
• pp.376-381
• /
• 2003

Ultra precision diamond cutting is a very efficient manufacturing method for optical parts such as HOE, Fresnel lenses, diffraction lenses, and others. During micro cutting, the rake angle is likely to become negative because the tool edge radius is considerably large compared to the sub-micrometer-order depth of cut. Depending on the ratio of the tool edge radius to the depth of cut, different micro-cutting mechanism modes appear. Therefore, the tool edge sharpness is the most important factor affecting the qualities of machined parts. That is why diamond especially mono-crystal diamond, which has the sharpest edge among all other materials is widely used in micro-cutting. The question arises, given a diamond tool, what is the minimum (critical) depth of cut to get continuous chips while in the cutting process\ulcorner In this paper, the micro machinability around the critical depth of cut is investigated in micro grooving with a diamond tool, and introduce the minimizing method of cutting depth using vibration cutting. The experimental results show the characteristics of micro cutting in terms of cutting force ratio (Fx/Fy), chip shape, surface roughness, and surface hardeing around the critical depth of cut.

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.13 no.6
• /
• pp.1-9
• /
• 2004

For improvement of productivity and cutting tool lift, cutting force in end milling needs to be predicted accurately. In order to analyze cutting force, the cutting dynamics was modelled mathematically by using chip load, cutting geometry, and the relationship between cutting forces and the chip load. Specific cutting force coefficients of the cutting dynamics model were obtained by average cutting forces, tool diameter, cutting speed, fled, axial depth and radial depth of cut. The effects of the cutting conditions on the specific cutting force constants in milling were studied. The model is verified through comparisons of model predicted cutting forces with measured cutting forces obtained from machining experiments.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2004.04a
• /
• pp.93-98
• /
• 2004

A reasonable analysis of cutting force in end milling may give much advantage to improvement of productivity and cutting tool life. In order to analyze cutting force, the cutting dynamics was modelled mathematically by using chip load, cutting geometry, and the relationship between cutting forces and the chip load. Specific cutting constants of the cutting dynamics model were obtained by average cutting forces, tool diameter, cutting speed, feed, axial depth, and radial depth of cut. The effects of the cutting conditions on the specific cutting force constants in milling were studied. The model is verified through comparisons of model predicted cutting forces with measured culling forces obtained from machining experiments

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.13 no.4
• /
• pp.9-15
• /
• 2004

A reasonable analysis of cutting force in end milling may give much advantage to improvement of productivity and cutting tool life. In order to analyze cutting force, the cutting dynamics was modelled mathematically by using chip load, cutting geometry, and the relationship between cutting forces and the chip load. The specific cutting constants of the cutting dynamics model were obtained by average cutting forces, tool diameter, cutting speed, feed, axial depth, and radial depth of cut. The model is verified through comparisons of model predicted cutting forces with measured cutting forces obtained from machining experiments. The results showed good agreement and from that we could predict reasonably the cutting forces in end milling.

• Journal of the Korean Society for Precision Engineering
• /
• v.21 no.11
• /
• pp.38-45
• /
• 2004

This paper discusses the minimum cutting thickness with a continuous chip in sub-micrometer order precision diamond cutting. An ultra precision cutting model is proposed, in which the tool edge radius and the friction coefficient are the principal factors determining the minimum cutting thickness. The experimental results verify the proposed model and provide various supporting evidence. In order to reduce the minimum cutting thickness a vibration cutting method is applied, and the effects are investigated through a series of experiments under the same conditions as conventional cutting method.

• Journal of Mechanical Science and Technology
• /
• v.17 no.2
• /
• pp.239-245
• /
• 2003

Ultra precision diamond cutting is a very efficient manufacturing method for optical parts such as HOE, Fresnel lenses, diffraction lenses, and others. During micro cutting, the rake angle is likely to become negative because the tool edge radius is considerably large compared to the sub-micrometer-order depth of cut. Depending on the ratio of the tool edge radius to the depth of cut, different micro-cutting mechanism modes appear. Therefore, the tool edge sharpness is the most important factor which affects the qualities of machined parts. That is why diamond, especially monocrystal diamond which has the sharpest edge among all other materials, is widely used in micro-cutting. The majar issue is regarding the minimum (critical) depth of cut needed to obtain continuous chips during the cutting process. In this paper, the micro machinability near the critical depth of cut is investigated in micro grooving with a diamond tool. The experimental results show the characteristics of micro-cutting in terms of cutting force ratio (Fx/Fy), chip shape, surface roughness, and surface hardening nea. the critical depth of cut.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.12 no.1
• /
• pp.84-89
• /
• 2013

Titanium used in industry has been widely applied for aerospace engine, structures and spacecraft exterior, etc. because the titanium is higher in strength compared to the steel and light in weight compared to the steel. This study is to investigate the effect of cutting depth and cutting time on the spindle speed and feed rate of vertical machining center as a parameter to find the rough cutting time and cutting depth in the medium speed cutting machining of the titanium alloy. It is found that the cutting machining heat are increased as the cutting depth, feed rate, cutting time and spindle speed are raised.

• Journal of the Korean Society for Precision Engineering
• /
• v.9 no.4
• /
• pp.147-153
• /
• 1992

This study was undertaken to investigate the cutting behaviour of super duralumin (A2024-T3) with sintered carbide tool(P20). The cutting test was carried out under different conditions such as cutting speed, cutting depth and rake angle, etc. The specific cutting force Kc and Kt of vertical and radial forces decreases as cutting speed increases, especially the decrease rate of Kt becomes larger than of Kc as cutting speed increases. Kc and Kt in small cutting depth are much affected by work-hardening of surface layer. The chip width and shear angle become layer as cutting depth increases, especially chip width at feed of 0.1mm almost approaches cutting width. Relation between the friction coefficient of chip side and tool rake angle side can make the modelization studying the built-up edge size. The shear angle model equation of super duralumin generally agree with theory of Ernst-Merchant.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 1999.10a
• /
• pp.34-39
• /
• 1999

If the on-line cutting conditions (e.g. speed, feedrate, radial and axal depth of cuts) can be identified in an end milling process, much information about cutting forces will be estimated from the cutting force model. Therefore, those estimated conditions can be applied to monitoring and control areas. In this paper, a real-time estimation algorithm for radial and axial depth of cuts is studied in end milling using the averaging cutting forces per tooth. The analytical estimation models of depth of cuts are derived from the geometric cutting force model. The validity of the estimation models is verified on a horizontal machining center through the experiments in various cutting conditions.