• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.6
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• pp.90-96
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• 1998

The ductile cast iron is austempered at 300, 350 and 40$0^{\circ}C$ temperature in order to investigate the basic factors for monitoring drill wear in automatic production process, and cutting force and AE RMS signals are measured with changing cutting condition for ADI(Austempered Ductile Cast Iron) with different mechanical properties. The signals of cutting force were influenced by cutting speed and feedrate greatly. On the other hand AE RMS signals are influenced by cutting speed where as it is not related with feedrate. As the depth of drilling increases, cutting force shows a slow increase and the value of AE RMS increases until the range of h/d=4. But over the range it increases greatly due to an amount of chip discharge and friction with inner wall of drilling hole, etc. As the drill diameter increases at a constant depth of drilling. Cutting force increases linearly, but the level of AE RMS does not increases linearly due to circumferential velocity and great influence of h/d.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1996.10a
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• pp.96-100
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• 1996

So far the analysis and modeling of cutting process is studied commonly assumed as being linear stochastic or chaotic without experimental verification. So we verified force signals of cutting process(ball end-milling) is low-dimensional chaos by calculating Lyapunov Exponents. reconstructing attractor using time delay coordinates and calcula-ting it's fractal dimension.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.7
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• pp.143-148
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• 2001

In this study, a mechanistic model of cutting force components in up and down end milling process is presented. Using this cutting force model of 4-tooth endmills with various helix angles, cutting force variation of inconel 718 has been predicted. Predicted values of cutting force components are coincide well with the measured ones. As helix angle increases, overlapping effects of the active cutting edges increase. In up endmilling the magnitudes of radial and feed cutting force componts FX and FY are lowest when the helix angle is $40\{\circ}$, but in down endmilling the magnitudes of these values increase slightly as helix angle becomes large.

• Industrial Engineering and Management Systems
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• v.9 no.3
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• pp.242-250
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• 2010

For economical and environmental reasons, the aim of this research is hence to monitor the cutting conditions with the dry cutting, the wet cutting, and the mist cutting to obtain the proper cutting condition for the plain carbon steel with the ball end milling based on the consideration of the surface roughness of the machined parts, the life of the cutting tools, the use of the cutting fluids, the density of the particles of cutting fluids dispersed in the working area, and the cost of cutting. The experimentally obtained results of the relation between tool wear and surface roughness, the relation between tool wear and cutting force, and the relation between cutting force and surface roughness are correspondent with the same trend. The phenomena of surface roughness and tool wear can be explained by the in-process cutting forces. The models of the tool wear with the cutting conditions and the cutting times are proposed to estimate the tool cost for the different cooling strategies based on the experimental data using the multiple regression technique. The cutting cost is calculated from the costs of cutting tool and cutting fluid. The mist cutting gives the lowest cutting cost as compared to others. The experimentally obtained proper cutting condition is determined based on the experimental results referring to the criteria.

• Transactions of the Korean Society of Mechanical Engineers
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• v.13 no.3
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• pp.424-432
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• 1989

A mathematical model is developed for determination of the dynamic cutting force from static cutting data. The dynamic cutting force is analytically expressed by the static cutting coefficient and the dynamic cutting coefficient which can be determined from the cutting mechanics. The proposed model is verified by the chatter stability charts. A good agreement was shown between the stability limits predicted by the theory and the critical width of cut determined by experiments. The static cutting coefficient dominates high speed chatter stability, while the dynamic cutting coefficient dominates low speed chatter stability.

• Design & Manufacturing
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• v.16 no.3
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• pp.39-43
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• 2022

In this study, we designed an vibration cutting tool that can achieve improvements such as low cutting force, interrupted chip evacuation and better surface quality of cutting performance to obtain high-quality surface roughness and improvement of tool wear, which is an issue in the machining of high-hardness mold steel. Among the resonance frequency modes of the vibration cutting tool, the bending mode was used to maximize the driving amplitude of the vibration tool tip, and the resonance frequency was confirmed through the finite element method. After measuring the actual resonant frequency of the designed tool using an optical fiber sensor, the cutting force and machining surface of vibration cutting and conventional cutting were compared and analyzed in the turning process of high hardness mold steel (STAVAX). As a result of the experiment, the cutting force was reduced by about 20 % compared to the conventional cutting process, and the surface roughness was also improved by about 60 %. This study suggested that the tool wear and surface quality of high-hardness steel can be improved through the vibration cutting method in the machining of high hardness mold steel.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1998.03a
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• pp.30-34
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• 1998

In-process monitoring of cutting conditions and tool wear is important for improving productivity. This paper is concerned with on-line monitoring of tool wear and cutting force in end milling operation. The experimental study deals with the relations between flank wear and cutting force signal. Tool wear is detected by monitoring of cutting signal. A monitoring procedure is shown in this paper. The influence of flank wear on cutting signal activity was examined. The results are presented in the form of graphs. The analysis of the cutting signal and flank wear curves provides useful indicators of unacceptable wear development in the tool.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.8
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• pp.115-121
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• 1997

The in-process detection of the tool wear is one of the most important technologies in completely auto- matic operation of machine tool. In this research, using the tools having flank wear, the dynamic compo- nent of cutting forces is considered to be available for identifying the cutting process. In order to investi- gate this relation in detail, the cutting forces in turning of workpiece made of aluminum were measured by dynamometer of piezoelectric type, and the dynamic components of cutting force were analyzed. The fre- quency analysis, probability density analysis and RMS analysis of the dynamic components were carried out independently. Through the experiments, the characteristics of the tool system have a large effect on the dynamic component of cutting forces. As a result, it is shown that the dynamic cutting force was able to detect flank wear accurately.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.11
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• pp.163-170
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• 1997

End milling experiments are conducted to investigate characteristics of acoustic emission (AE) and cutting force singals due to tool fracture. The AE signals are obtained with a sensor attached to cutting fluid discharge nozzle. Tool states are identified with scanning electron microscopy and optical microscopy. It is demonstrated that the AE signals provide reliable informations about the cutting processes and tool states. Morever, tool fracture can be detected successfully using both the AE count rate and the standard deviation of principal cutting force.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.3 s.180
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• pp.39-46
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• 2006

In this work a dynamic cutting force model in ball end milling of inclined surface is introduced. To represent the complex cutting geometry in ball end milling of inclined surface, workpiece is modeled with Z-map method and cutting edges are divided into finite cutting edge elements. As tool rotates and vibrates, a finite cutting edge element makes two triangular sub-patches. Using the number of nodes in workpiece which are in the interior of sub-patches, instant average uncut chip thickness is derived. Instant dynamic cutting forces are computed with the chip thickness and cutting coefficients. The deformation of cutting tool induced by cutting farces is also computed. With iterative computation of these procedures, a dynamic cutting force model is generated. The model is verified with several experiments.