• 한국공작기계학회논문집
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• 제16권5호
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• pp.108-114
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• 2007

A new cutting force estimating approach and machining state monitoring examples are presented which uses a cylindrical displacement sensor built into the spindle. To identify the tool-spindle system dynamics with frequency up to 2 kHz, a home-built electro-magnetic exciter is used. The result is used to build an algorithm to extract the dynamic cutting force signal from the spindle error motion; because the built-in spindle sensor signal contains both spindle-tool dynamics and tool-workpiece interactions. This sensor is very sensitive and can measure broadband signal without affecting the system dynamics. The main characteristic is that it is designed so that the measurement is irrelevant to the geometric errors by covering the entire circumferential area between the target and sensor. It is also very simple to be installed. Usually the spindle front cover part is copied and replaced with a new one with this sensor added. It gives valuable information about the operating condition of the spindle at any time. It can be used to monitor cutting force and chatter vibration, to predict roughness and to compensate the form error by overriding spindle speed or feed rate. This approach is particularly useful in monitoring a high speed machining process.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2001년도 추계학술대회(한국공작기계학회)
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• pp.51-56
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• 2001

This work describes reduction of disturbance created by driving actuator in milling process. To the end, controller includes disturbance dynamics. Experimently it is shown that steady disturbance can be rejected to a certain degree.

• 대한기계학회논문집A
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• 제23권6호
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• pp.979-987
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• 1999

In a high precision vertical machining center, the estimation of cutting forces is important for many reasons such as prediction of chatter vibration, surface roughness and so on, and cutting forces are difficult to predict because they are very complex and time variant. In order to predict the cutting forces of end-milling process for various cutting conditions, a mathematical model is important and this model is based on chip load, cutting geometry, and the relationship between cutting forces and chip loads. Specific cutting force coefficients of the model have been obtained as interpolation function types by averaging farces of cutting tests. In this paper, the coefficients are obtained by neural network and the results of the conventional method and those of the proposed method are compared. The results show that the neural network method gives more correct values than the function type and that in teaming stage as the omitted numbers of experimental data increases the average errors increase.

• 대한기계학회논문집A
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• 제40권7호
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• pp.685-692
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• 2016

커팅헤드 어태치먼트는 굴삭기에 부착되어 사용되며 절삭 도구인 픽커터가 커팅헤드에 배열되어 암석이나 낙후된 건물을 파쇄 또는 절삭하는 작업에 사용된다. 암석을 절삭할 때 픽 커터의 배열은 절삭 성능과 연관성이 있는 요소이다. 본 연구는 픽 배열 설계 자동화를 수행하여 설계 소요 시간 및 검증 시간을 단축시켰으며, 배열에 따른 시스템의 거동을 예측하는데 활용하였다. 픽 배열 설계 자동화 방법은 RecurDyn/ProcessNet을 통해 수행하였으며, 설계 자동화 프로그램은 Drum set, Pick load 그리고 Pick arrangement의 세 부분으로 나누어 진행하였다. 이를 통해 커팅헤드 어태치먼트의 설계 비용 절감과 다양한 메커니즘 별 전용 어태치먼트의 설계에 활용할 수 있다.

• 한국생산제조학회지
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• 제8권3호
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• pp.42-51
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• 1999

An experimental modeling of cutting and structural dynamics and the on-line detection of malfunction process is substantial not only for the investigation of the static and dynamic characteristics of cutting process but also for the analytic realization of diagnostic systems. In this regard, We have discussed on the comparative assessment of two recursive time series modeling algorithms that can represent the machining process and detect the abnormal machining behaviors in precision round shape machining such as turning, drilling and boring in mold and die making. In this study, simulation and experimental work were performed to show the malfunctioned behaviors. For this purpose, two new recursive approach (REIVM, RLSM) were adopted fur the on-line system identification and monitoring of a machining process, we can apply these new algorithm in real process for the detection of abnormal machining behaviors such as chipping, chatter, wear and round shape lobe waviness.

• 한국기계가공학회지
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• 제20권10호
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• pp.88-94
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• 2021

Machining operations require the removal of chips to keep the water-soluble cutting oil clean and fresh throughout the operation time. Water-soluble cutting oil for metal processing is diluted using a 3-8% solution in water which is generally replaced every three to six months. This study aims to develop multiple purification devices to efficiently remove fine contaminating particles from water-soluble cutting oil. The 2D concept designs were created using AutoCAD. The designs were drawn using the 3D modelling feature of CATIA. Flow analysis was performed in a bubble purifier using Ansys computational fluid dynamics (CFD). This analysis has aided in improving the design and structure of the device to create the final prototype. Experiments were conducted to check the prototype's performance. Comparisons of the effects of each process variable on the experiment was carried out using ANOVA.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.199-202
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• 2005

High speed milling process is emerging as an important fabrication process benefits include the ability to fabricate micro and meso-scale parts out of a greater range of materials and with more varied geometry. It also enables the creation of micro and meso-scale molds for injection molding. Factors affecting surface roughness have not been studied in depth for this process. A series of experiments has been conducted in order to begin to characterize the factors affecting surface roughness and determine the range of attainable surface roughness values for the high speed milling process. It has previously been shown that run-out creates a greater problem for the dimensional accuracy of parts created by high speed milling process. And run-out also has a more significant effect on the surface quality of milled parts. The surface roughness traces reveal large peak to valley variations. This run-out is generated by spindle dynamics and tool geometry. In order to investigate the relationship between tool setting errors and surface roughness end tilted mills were used to cut aluminum samples. The results indicate that tool setting errors have significant effects on surface roughness and cutting forces.

• 한국생산제조학회지
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• 제6권4호
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• pp.101-107
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• 1997

In order to detect and suppress chatter in turning process, a stability control methodology was studied through manipulation of spindle speeds regarding to chatter frequencies, The chatter frequency was identified by monitoring and signal processing of sound pressure during turing on a lathe. The stability control methodology can select stable spindle speeds without knowing a prior knowledge of machine compliances and cutting dynamics. Reliability of the developed stability control methodology was verified through turing experiments on an engine lathe. Experimental results show that a microphone is an excellent sensor for chatter detection and control .

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1992년도 추계학술대회 논문집
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• pp.344-348
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• 1992

This paper presents a new methodology for on-line tool breakage detection by sensor fusion concept of an acoustic-emission (AE) sensor. A built-in piezoelectric force sensor was used to measure cutting force instead of a tool dynamometer to preserve the machine tool dynamics. he sensor was inserted in the tool turret housing of an NC lathe. FEM analysis was carried out to locate the most sensitive position for the sensor. When a tool is broken, the explicit changes of signals' pattern take place. A burst-type AE signal increases abruptly. Followingly, a cutting force drops significantly. Therefore a burst of AE signal is used as a triggering signal to inspect the following cutting force. Significant drop of cutting force is utilized to detect tool breakage. The algorithm was implemented in a DSP board for in-process tool breakage detection. The proposed monitoring system was capable of a good applicable tool breakage detection.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 춘계학술대회 논문집
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• pp.708-713
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• 2000

A research on the AFC(Auto Feedrate Control) by a fuzzy controller using a tool dynamometer and motor currents was conducted. For simulations, cutting dynamics of end-milling process was modeled by geometric relationship between tool and work-piece. The fuzzy logic controller was employed to track the desired cutting force and showed good performance in simulations and several experiments. The spindle motor currents was modeled to estimate cutting force and successfully used for the AFC.