• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.5
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• pp.50-56
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• 2014

A technique based on the finite element method (FEM) is used in the simulation of metal cutting process. This offers the advantages of the prediction of the cutting force, the stresses, the temperature, the tool wear, and optimization of the cutting condition, the tool shape and the residual stress of the surface. However, the accuracy and reliability of prediction depend on the flow stress of the workpiece. There are various models which describe the relationship between the flow stress and the strain. The Johnson-Cook model is a well-known material model capable of doing this. Low-alloy steel is developed for a dry storage container for used nuclear fuel. Related to this, a process analysis of the plastic machining capability is necessary. For a plastic processing analysis of machining or forging, there are five parameters that must be input into the Johnson-Cook model in this paper. These are (1) the determination of the strain-hardening modulus and the strain hardening exponent through a room-temperature tensile test, (2) the determination of the thermal softening exponent through a high-temperature tensile test, (3) the determination of the cutting forces through an orthogonal cutting test at various cutting speeds, (4) the determination of the strain-rate hardening modulus comparing the orthogonal cutting test results with FEM results. (5) Finally, to validate the Johnson-Cook material parameters, a comparison of the room-temperature tensile test result with a quasi-static simulation using LS-Dyna is necessary.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.8
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• pp.693-698
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• 2015

Recently, the quality of products after the corresponding machining processes were scrutinized in the interest of maintaining a high product-quality standard. The structure and stability of machine tools are important for the prediction of product quality. A structural analysis needs to be carried out to achieve the stable design of machine tools before the initial design stage in the manufacturing process of a precision product. In this study, a structural analysis was carried out using a finite element analysis (FEA) simulation to obtain the design stability of the main parts of a grinding machine. The sizes and locations of both the maximum stress and deformation in consideration of the cutting force of the chuck, tail stock, and bearing of the grinding machine were analyzed. Finally the grinding machine was successfully developed.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.3
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• pp.66-74
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• 1997

In a high speed and high precision vertical machining center, chatter vibration is easily generated due to unbalanced masses in rotating parts and changtes of cutting forces. In this paper, modal test is performed to obtain modal parameters of the vertical machining center. In order to predit the cutting force of endmilling process for various cutting conditions, a mathematical model is given and this model is based on chip load, cutting geometry, and relationship between cutting forces and the chip load. Specific cutting constants of the model are obtained by averaging forces of cutting tests. The interactions between the dy- namic characteristics and cutting dynamics of the vertical machining center make the primary and the secondary feedback loops, and we make use of the equations of system to predict the chatter vibration. The chatter prediction is formulated as linear differential-differene equations, and simulated for several cases. Trends of vibration as radial and axial depths of cut are changed are shown and compared.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.4
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• pp.329-337
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• 2015

In this paper, a simulation based estimation method of energy consumption of the spindle and feed drives for the NC machine tool during the cutting process is proposed. To predict energy consumption of the feed drive system, position, velocity, acceleration and jerk of the table are analyzed based on NC data and then the power and energy are calculated considering friction force and mass of the stages. Energy consumption of the spindle is estimated based on models from acceleration motion of rotating parts, friction torque and power loss of motors. Moreover, simulation models of cutting power and energy for the material removal along the NC tool paths are proposed.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.12
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• pp.3195-3201
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• 1994

In order to analytically predict tapping torque and thrust force in high speed tapping, a cutting model for main cutting edge with a uniformly restricted tool-chip contact area were developed. From this model equations are derived for the prediction of tapping torque given the cutting conditions, tap geometry, and an empirical factor which is related to the workmaterial. Computed values of torque is shown to compare favorably with those obtained from tapping tests on 16MnCr5. The applied torque about the cutting edge of teeth at lead chamfer is estimated respectively and it is shown that observed value is gradually decreased with following teeth.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.121-127
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• 2008

Micro end-milling has been becoming an important machining process to manufacture a number of small products such as micro-devices, bio-chips, micro-patterns and so on. Despite the importance of micro end-milling, many related researches have given grand efforts to micro end-milling phenomenon, for example, micro end-milling mechanism, cutting force modeling and machinability. This paper strongly concerned actual problem, micro tool deflection, which causes excessive machining errors on the workpiece. To solve this problem, machining error prediction method was proposed through a series of test micro cutting and analysis of their SEM images. An iterative algorithm was applied in order to obtain corrected tool path which allows reducing machining errors in spite of tool deflection. Experiments are carried out to validate the proposed approaches. In result, remarkable error reduction could be obtained.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.381-383
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• 2005

This paper is concerned with the prediction of micro structural changes of Al alloys during cryogenic rolling using an Eulerian finite element analysis. The main objective of cryogenic rolling is to obtain ultra-fine grains by severe plastic deformation at the extremely low temperature. Thereby, this simulation focuses on micro structural developments - the texture development and the changes in the size and shape of grains. The former one may be modeled using a crystal plasticity theory while the other can be predicted by a streamline technique. Applications to three pass rolling are given.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.3
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• pp.114-121
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• 1997

In this paper, the automated initial process planning for 3-axis NC machining of sculptured surfaces is persented. The solution algorithms determining three process planning functions, i.e. machining feasibility, setup orientation and feasible machine selection are developed. The machining feasibility is determined by means of BSM(Binary Spherical Map) which derives its solution quickly in algebraic form, and the setup orientation is determined so that the cutting force is minimized. Finally, the feasible machine is determined by computing the minimum motion ranges of each control axisl. The developed algorithms are tested by numerical simulations, convincing they can by readily implemented on the CAD/CAM system as a process planner.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.2
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• pp.71-76
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• 2003

A virtual machine tool (VMT) is presented in this two-part paper. In Part 1, the analytical foundation for a virtual machining system is developed, which is envisioned as the foundation for a comprehensive simulation environment capable of predicting the outcome of cutting processes. The VHT system undergoes "pseudo-real machining", before actual cutting with a CNC machine tool takes place, to provide the proper cutting conditions for process planners and to compensate or control the machining process in terms of the productivity and attributes of the products. The attributes can be characterized by the machined surface error, dimensional accuracy, roughness, integrity, and so forth. The main components of the VMT are the cutting process, application, thermal behavior, and feed drive modules. In Part 1, the cutting process module is presented. When verified experimentally, the proposed models gave significantly better prediction results than any other methods. In Part 2 of this paper, the thermal behavior and feed drive modules are developed, and the models are integrated into a comprehensive software environment.vironment.

• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.1-13
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• 2016

The increase of consumer needs for quality metal cutting related products with more precise tolerances and better product surface roughness has driven the metal cutting industry to continuously improve quality control of metal cutting processes. In this paper, two different approaches are discussed. First, design of experiments (DOE) is used to determine the significant factors and then fuzzy logic approach is presented for the prediction of surface roughness. The data used for the training and checking the fuzzy logic performance is derived from the experiments conducted on a CNC milling machine. In order to obtain better surface roughness, the proper sets of cutting parameters are determined before the process takes place. The factors considered for DOE in the experiment were the depth of cut, feed rate per tooth, cutting speed, tool nose radius, the use of cutting fluid and the three components of the cutting force. Finally the significant factors were used as input factors for fuzzy logic mechanism and surface roughness is predicted with empirical formula developed. Test results show good agreement between the actual process output and the predicted surface roughness.