• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.40-45
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• 2016

Interrupted cutting has different cutting characteristics compared with continuous cutting. In interrupted cutting, the workpiece has a groove that regularly impacts the cutting tool and workpiece. Therefore, tool damage occurs rapidly, and this increases the cutting force and surface roughness. In this study, we performed interrupted cutting of carbon steel for machine structure (SM45C) using a coated carbide tool (TT7100). To predict the cutting force, we analyzed the experimental results with a regression analysis. The results were as follows: We confirmed that the factors affecting the principal force and radial force were cutting speed, depth of cut, and feed rate. From the multi-regression analysis, we deduced regression equations, and their coefficients of determination were 89.6, 89.27, and 28.27 for the principal, radial, and feed forces, respectively. This means that the regression equations were significant for the principal and radial forces but not for the feed force.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.237-240
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• 2004

Indexable end mills, which consist of inserts and cutter body, have been widely used in roughing of parts in the mold industry. The geometry and distribution of inserts on cutter body are determined by application. This paper proposes analytical cutting force model for indexable flat end-milling process. Developed cutting force model uses the cutting-condition-independent cutting force coefficients and considers runout, cutter deflection and size effect for the accurate cutting force prediction. Unlike solid type endmill, the tool geometry of indexable endmill is variable according to the axial position due to the geometry and distribution of inserts on the cutter body. Thus, adaptive algorithm that calculates tool geometry data at arbitrary axial position was developed. Then number of flute, angular position of flute, and uncutchip thickness are calculated. Finally, presented model was validated through some experiments with aluminum workpiece.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.185-188
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• 1995

In this paper, We have analyzed dynamic characteristics of cutting force. Test materials are used in the tempered carbon steek and non-tempered carbon steel. The obtained results ase as follows: 1. Cutting force is smaller non-tempered carbon steel than tempered carbon steel when feed speed make a change. 2. Specific cutting force is smaller non-tempered carbon steel than tempered caron steel when cutting depth make a change

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.907-911
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• 2000

In this study, a modified model for prediction of cutting force components in down end milling process is presented. Using this cutting force components of 4-tooth endmills with various helix angles have been predicted. Predicted values of cutting force components are well coincide with the measured ones. As helix angle increases overlapping effects of the active cutting edges increase and as a result the amplitudes of cutting force components decrease.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.150-156
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• 1996

Static variations of cutting forces are estimated using spindle motor current. Static sensitivity of spindle motor current is higher than feed motor current. The linear relationship between the cutting force and RMS value of the spindle motor current is obtained. Using cutting force estimation, tool overload in milling process can be well detected, and cutting force is regulated at a constant level by feedrate adaptive control.

• Journal of Mechanical Science and Technology
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• v.16 no.7
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• pp.873-881
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• 2002

In this paper, a on-line estimation method of the radial immersion angle using cutting force is presented. The ratio of cutting forces in feed and cross-feed directions acting on the single tooth at the immersion angle is a function of the immersion angle and the ratio of radial to tangential cutting force. It is found that the ratio of radial to tangential cutting force is not affected by cutting conditions and axial rake angle, which implies that the ratio determined by one preliminary experiment can be used regardless of the cutting conditions for a given tool and workpiece material. Using the measured cutting force during machining and predetermined ratio, the radial immersion ratio is estimated in process. Various experimental results show that the proposed method works within 5% error range.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.4
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• pp.38-45
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• 1997

A new dynamic model for the cutting process inb the end milling process is developed. This model, which describes the dynamic response of the end mill, the chip load geometry including tool runout, the dependence of the cutting forces on the chip load, is used to predict the dynamic cutting force during the end milling process. In order to predict accurately cutting forces and tool vibration, the model which uses instantaneous specific cutting force, inclueds both regenerative effect and penetration effect, The model is verified through comparisons of model predicted cutting force with measured cutting force obtained from machining experiments.

• Journal of the Korean Society for Precision Engineering
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• v.1 no.3
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• pp.95-105
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• 1984

The purpose of this paper is to predict the cutting force, utilizing new model of double cutting edge which has normal rake angle and tool inclination angle. Changing side, back rake angle and side cutting edge angle in the new model. Three dimensional cutting force was obtained by the use of .eta. /c=i proposed by Stabler and energy method for three dimen- sional cutting force. Theoretical results has been calculated with development of optimization algorism which can be put into three dimensional theory, using the method of least square with orthogonal cutting data. IT is proved that three dimensional cutting force is to be predicted accurately only if orthogonal cutting force by equalizing theoretical result and experimental result has been calculated.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.4
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• pp.105-110
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• 1998

In this study, statistical and neural network methods were used to recognize the cutting tool states. This system employed the tool dynamometer and cutting force signals which are processed from the tool dynamometer sensor using linear discriminent function. To learn the necessary input/output mapping for turning operation diagnosis, the weights and thresholds of the neural network were adjusted according to the error back propagation method during off-line training. The cutting conditions, cutting force ratios and statistical values(standard deviation, coefficient of variation) attained from the cutting force signals were used as the inputs to the neural network. Through the suggested neural network a cutting tool states may be successfully diagnosed.

• Journal of the Korean Society for Precision Engineering
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• v.5 no.1
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• pp.84-93
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• 1988

The on-line detection of the chip flow is one of the most important technologies in com- pletly automatic operation of machine tool, such as FMS and Unmanned Factories. This problem has been studied by many researchers, however, it is not solved as yet. For the recognition of chip flow in this study, the dynamic cutting force components due to the chip breaking were measured by dynamometer of piezo-electric type, and the frequency components of cutting force were also analyzed. From the measured results, the effect of cutting conditions and tool geometry on the dynamic cutting force component and chip formation were investigated in addition to the relationships between frequency of chip breaking (fB) and side serrated crack (fC) of chip. As a result, the following conclusions were obtaianed. 1) The chip formations have a large effect on the dynamic cutting force components. When chip breaking takes place, the dynamic cutting force component greatly increases, and the peridoic components appear, which correspond to maximum peak- frequency. 2) The crater wear of tool has a good effect on the chip control causing the chiup to be formed as upward-curl shape. In this case, the dymamic cutting force component greatly increases also 3) fB and fC of chip are closely corelated, and fC of chips has a large effect on the change of the situation of chip flow and dynamic cutting force component. 4) Under wide cutting conditions, the limit value (1.0 kgf) of dynamic cutting force component exists between the broken and continuous chips. Accordingly, this value is suitable for recognition of chip flow in on-line control of the cutting process.