• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.11
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• pp.2664-2675
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• 1993

In this paper, the effects of chip breaker configuration on cutting forces for various cutting conditions are investigated and a method for predicting cutting forces effectively for chip breaker insert in milling is described. Based on the shear plane model and the relevant equations already existing for the relation among the parameters, the method makes use of the analytic geometric approach considering the configuration of cutting too by a 3-dimensional coordinate transformation matrix. The groove type chip breaker insert is modeled to be a double rake insert, represented by the first radial rake angle, the second radial rake angle and the length of land, and the program analyzing the cutting forces is developed. The program capability is verified by comparing the results with the experimental ones for a single cutter; and in case of primary cutting forces, the results of simulation and experiments agree very well showing 2%~16.7% difference within the feed rate range investigated.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.4
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• pp.271-280
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• 2016

Predicting cutting forces in machine tools is essential to productivity improvement and process control in the manufacturing field. Furthermore, milling machining is more complicated than turning machining. Therefore, several studies have been conducted previously to simulate milling forces; this study aims to simulate the cutting forces in milling machines using multi-layered neural networks. In the experiments, the number of layers in these networks was 3 and 4 and the number of neurons in the hidden layers was varied from 20 to 200. The root mean square errors of simulated cutting force components were obtained from taught and untaught data for the various neural networks. Results show that the error trends for untaught data were non-uniform because of the complex nature of the cutting force components, which was caused by different cutting factors and nonlinear characteristics coming into play. However, trends for taught data showed a very good coincidence.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.179-184
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• 1995

A new cutting parameter is defined in the spherical part of ball end-mill cutter. A series of slot cutting experiments were carried out to obtain the cutting parameter. The cutter contact area is expressed as the grid posiotion in the cutting plane using Z map. The cutting forces in each grid are calculated and saved as force map, prior to the average cutting forces calculation. The cutting force, in the arbitrary cutting area, can be easily calculated by summing up the cutting forces of the engaged grid in the force map. This model was verified in the inclined surface cutting by cutting test of a cylindrical part.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.3_1spc
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• pp.489-495
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• 2013

This study analyzed thevariation in the cutting force when the cutting area of a terrace volume is machined, which is generally left after the rough cutting of a sculptured surface. The numerically simulated results for the cutting forces are compared with cutting force measurements by considering the theoretical prediction of the cutting area formation and specific cutting volume. The variation in the cutting force is measured using a dynamometer installed on a machining center for 19 different kinds of test pieces, which are selected according to the variation in the terrace volume factor, tool diameter factor, and cutting depth factor. As a result, it is verified that the cutting forces evaluated by the numerical analysis coincide with the measured cutting forces, and it is proposed as a practical cutting force prediction model.

• Journal of the Korean Society for Precision Engineering
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• v.11 no.4
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• pp.13-25
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• 1994

In order to design and improve a new machine tool, there is a need for a better understanding of the cutting force. In this paper, the computer programs were developed to predict not only the mean specific cutting pressure but also the cutting force. The simulated cutting forces in X, Y, Z directions resulted form the developed cutting force model were compared with the measured cutting forces in the time and frequency domains. The simulated cutting forces resulted from the new cutting force model have a good agreement with the measured force in comparison with these resulted from the existing cutting force model.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.239-244
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• 1999

Radial immersion ratio is an important factor to determine the threshold in face milling and should be estimated in process for automatic force regulation. In this paper, presented is a method of on-line estimation of radial immersion ratio using cutting force. When a tooth finishes sweeping, sudden drop of cutting forces occurs. These force drops are equal to the cutting forces that act on a single tooth at the swept angle of cut and can be acquired from cutting force signals in feed and cross-feed directions. The ratio of cutting forces in feed and cross-feed directions acting on the single tooth at the swept angle of cut is a function of the swept angle of cut and the ratio of radial to tangential cutting force. In the research, it is found that the ratio of radial to tangential cutting force is not affected by cutting conditions and axial rake angle. Therefore, the ratio of radial to tangential cutting force determined by just one preliminary experiment can be used regardless of the cutting conditions. Using the measured cutting forces and predetermined ratio, the redial immersion ratio is estimated. various experiments show that the radial immersion ratio can be estimated by the proposed method very well.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.10
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• pp.75-82
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• 2019

Few studies have been conducted regarding theoretical turning force modelling while considering cutting constant. In this paper, a new cutting force modelling technique was suggested which considers the specific cutting force coefficients for turning. The specific cutting force is the multiplication of the cutting force coefficient and uncut chip thickness. This parameter was used for experimental modelling and prediction of theoretical cutting force. These coefficients, which can be obtained by fitting measured average forces in several conditions, were used for the formulation of three theoretical cutting forces for turning. The cutting force mechanism was verified in this research and its results were compared with each of the experimental and theoretical forces. The deviation of force was incurred by a small amount in this model and the predicted force considering feed rate, nose radius, and radial depth shows a physical behavior in main force, normal force, and feeding force, respectively. Therefore, this modelling technique can be used to effectively predict three turning forces with different tool geometries considering cutting force coefficients.

• Journal of Biosystems Engineering
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• v.30 no.2 s.109
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• pp.75-80
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• 2005

Mechanical characteristics of flower stalks (scapes) of garlic such as shear forces, cutting forces, and modulus of elasticities were investigated as a preliminary research to develop a mechanical harvester of garlic bulbils. The average shear forces of garlic scapes was 0.642 N and the maximum and minimum shear forces were 1.42 and 0.25 N, respectively. The shear forces generally increased as the diameter of garlic scapes increased. There was no correlation between the modulus of elasticity and the diameter of garlic scapes and the average modulus of elasticity of garlic scapes was around $2.40\times10^7\;N/m^2$ There was also no correlation between the cutting force and the diameter of garlic scapes. As the downward speed of blade increased, the cutting force of garlic scapes decreased and reversed to increase. The cutting forces of the lower part garlic scapes were lower than those of the upper part. The range of cutting forces of the lower and the upper part of garlic scapes were 3.88-4.04 N and 4.29-4.93 N, respectively.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.370-375
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• 2004

This paper presents an accurate cutting simulation and feedrate scheduling system for CNC machining. This system is composed of a cutting simulation part and a feedrate scheduling part. The cutting simulation part computes the geometric informations and calculates the cutting forces in CNC machining. The cutting force model using cutting-condition-independent coefficients was introduced for flat end milling and ball end milling. The feedrate scheduling part divides original blocks of NC code into smaller ones with optimized feedrates to adjust the peak value of cutting forces to reference forces. Some machining examples show that the developed system can control the cutting force at desired levels.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.6
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• pp.1003-1009
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• 2013

This paper presents a simple procedure to obtain the instantaneous cutting force constants needed to predict milling forces. Cutting force data measured in a series of slot milling tests were used to determine the cutting force constants at different feed rates. The values of the cutting force constants were determined directly at the tool rotation angle that maximized the uncut chip thickness. Then, the instantaneous cutting force constant was obtained as a function of the instantaneous uncut chip thickness. This approach can greatly enhance the accuracy of the mechanistic cutting force model for end milling. In addition, the influences of several cutting parameters on the cutting forces, such as the tool helix angle and axial depth of cut, were discussed.