• Structural Engineering and Mechanics
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• v.70 no.4
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• pp.395-405
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• 2019

In the present work, the effects of cutting parameters on surface roughness parameters (Ra), tool wear parameters (VBmax), tool vibration (Vy) and material removal rate (MRR) during hard turning of AISI 4140 steel using coated carbide tool have been evaluated. The relationships between machining parameters and output variables were modeled using response surface methodology (RSM). Analysis of variance (ANOVA) was performed to quantify the effect of cutting parameters on the studied machining parameters and to check the adequacy of the mathematical model. Additionally, Multi-objective optimization based desirability function was performed to find optimal cutting parameters to minimize surface roughness, and maximize productivity. The experiments were planned as Box Behnken Design (BBD). The results show that feed rate influenced the surface roughness; the cutting speed influenced the tool wear; the feed rate influenced the tool vibration predominantly. According to the microscopic imagery, it was observed that adhesion and abrasion as the major wear mechanism.

• Journal of Mechanical Science and Technology
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• v.18 no.5
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• pp.770-779
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• 2004

This paper describes the micro cutting of wear resistant tungsten carbides using PCD (Poly-Crystalline Diamond) cutting tools in performance with SEM (Scanning Electron Microscope) direct observation method. Turning experiments were also carried out on this alloy (V50) using a PCD cutting tool. One of the purposes of this study is to describe clearly the cutting mechanism of tungsten carbides and the behavior of WC particles in the deformation zone in orthogonal micro cutting. Other purposes are to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, machined surface and tool wear rates by the outer turning of this alloy carried out using the PCD cutting tool during these various cutting conditions. A summary of the results are as follows: (1) From the SEM direct observation in cutting the tungsten carbide, WC particles are broken and come into contact with the tool edge directly. This causes tool wear in which portions scrape the tool in a strong manner. (2) There are two chip formation types. One is where the shear angle is comparatively small and the crack of the shear plane becomes wide. The other is a type where the shear angle is above 45 degrees and the crack of the shear plane does not widen. These differences are caused by the stress condition which gives rise to the friction at the shear plane. (3) The thrust cutting forces tend to increase more rapidly than the principal forces, as the depth of cut and the cutting speed are increased preferably in the orthogonal micro cutting. (4) The tool wear on the flank face was larger than that on the rake face in the orthogonal micro cutting. (5) Three components of cutting force in the conventional turning experiments were different in balance from ordinary cutting such as the cutting of steel or cast iron. Those expressed a large value of thrust force, principal force, and feed force. (6) From the viewpoint of high efficient cutting found within this research, a proper cutting speed was 15 m/min and a proper feed rate was 0.1 mm/rev. In this case, it was found that the tool life of a PCD tool was limited to a distance of approximately 230 m. (7) When the depth of cut was 0.1 mm, there was no influence of the feed rate on the feed force. The feed force tended to decrease, as the cutting distance was long, because the tool was worn and the tool edge retreated. (8) The main tool wear of a PCD tool in this research was due to the flank wear within the maximum value of $V_{max}$ being about 260 $\mu\textrm{m}$.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.4
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• pp.382-385
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• 2011

There is an immense need to obtain nanometric surface finish on optical glass owing to the advantage of improved performance of the components. But owing to brittleness and hardness, optical glass is one of the materials that is difficult to ultra-precision turning. According to the hypothesis of ductile mode machining, regardless of their hardness and brittleness, will undergo a transition from brittle to ductile machining region below a critical undeformed chip thickness. Below this threshold, it is suggested that the energy required for plastic formation. Thus, plastic deformation is the predominant mechanism of material removal in machining these materials in this mode. An experimental study is conducted diamond cutting for machining BK7 glass. The investigation presents the feasibility of achieving nanometric surface and the understanding the mechanism of cutting glass, proving the cutting edge radius effect.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.7
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• pp.44-50
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• 2009

High-pressured jetting is now widely used in the advanced cutting processes of polymers, metals, glass, ceramics and composite materials because of some advantages such as heatless and non-contacting cutting. Similarly to the focused laser beam machining, it is well known as a type of high-density energy processes. High-pressured jetting is going to be developed not only to minimize the cutting line width but also to achieve the short cutting time as soon as possible. However, the interaction behavior between a work piece and high-velocity abrasive particles during the high-pressured jet cutting makes the impact mechanism even more complicated. Conventional high-pressured jetting is still difficult to apply to precision cutting of micro-scaled thin work piece such as thin metal sheets, thin ceramic substrates, thin glass plates and TMM (Thin multi-layered materials). In this paper, we proposed the advanced high-pressured jetting technology by introducing a new abrasives supplying method and investigated the optimal process conditions of the cutting pressure, the cutting velocity and SOD (Standoff distance).

• Journal of the Korean Society for Precision Engineering
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• v.29 no.3
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• pp.279-288
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• 2012

The material removal mechanism in machining is significantly affected by the cutting edge geometry. Its effect becomes even more substantial when the depth of cut is relatively small as compared to the characteristic length which represents the shape and size of the cutting edge. Conventionally, radius or focal length has been employed as the characteristic length with the assumption that the shape of cutting edge is round or parabolic. However, in reality, there could be various ways to determine the radius or focal length even for the same tool edge profile, depending on the region to be considered as cutting edge in the measured profile and the constraints to be set in constructing the best fitted circle or parabola. In this regard, the present study proposes various models to determine the characteristic length in terms of radius or focal length. Their physical compatibility are validated by carrying out 2D orthogonal cutting experiments using inserts with a wide range of characteristic length ($30{\sim}180\;{\mu}m$ in terms of radius) and then by investigating the correlation between the characteristic length and the cutting forces. Such validation is based on the common belief that the larger the characteristic length is, the blunter the cutting edge is and the higher the cutting forces are. Interestingly, the results showed that the correlation is higher for the radius or focal length obtained with a constraint that the center of best fitted circle or the focus of the best fitted parabola should be on the bisectional line of the wedge angle of tool.

• Geomechanics and Engineering
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• v.23 no.6
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• pp.513-521
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• 2020

In this paper, due to the need for cutting cement-soil group pile composite foundation under the 7-story masonry structure of Zhenghe District and the shield tunnel of Zhengzhou Metro Line 5, a field test was conducted to directly cut cement-soil single pile composite foundation with diameter Ф=500 mm. Research results showed that the load transfer mechanism of composite foundation was not changed before and after shield tunnel cut the pile, and pile body and the soil between piles was still responsible for overburden load. The construction disturbance of shield cutting pile is a complicated mechanical process. The load carried by the original pile body was affected by the disturbance effect of pile cutting construction. Also, the fraction of the load carried by the original pile body was transferred to the soil between the piles and therefore, the bearing capacity of composite foundation was not decreased. Only the fractions of the load carried by pile and the soil between piles were distributed. On-site monitoring results showed that the settlement of pressure-bearing plates produced during shield cutting stage accounted for about 7% of total settlement. After the completion of pile cutting, the settlements of bearing plates generated by shield machine during residual pile composite foundation stage and shield machine tail were far away from residual pile composite foundation stage which accounted for about 15% and 74% of total settlement, respectively. In order to reduce the impact of shield cutting pile construction on the settlement of upper composite foundation, it was recommended to take measures such as optimization of shield construction parameters, radial grouting reinforcement and "clay shock" grouting within the disturbance range of shield cutting pile construction. Before pile cutting, the pile-soil stress ratio n of composite foundation was 2.437. After the shield cut pile is completed, the soil around the lining structure is gradually consolidated and reshaped, and residual pile composite foundation reaches a new state of force balance. This was because the condensation of grouting layer could increase the resistance of remaining pile end and friction resistance of the side of the pile.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.105-108
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• 1995

So far,in deep drilling process there are several manufacturing problems such as hole deviation, hole over size, circularity,straightness and surface roughness. Whit regard to these problems, we atudied the abrasion process on carbided tip of BTA drill and got the follow test results through the abrasion characteristic test and analysis on cutting mechanism for the drill tooth and guide pad. 1) In SM55C drilling process, the most stable and reasonable drilling speed range for optmum abrasion characteristic of drill tooth was 60m.min. 2) The total drilling torque was about 60kg .deg.cm on condition drilling speed 60m/min and 0.15mm/rev. These results show that the theoretical burnising torque is well accord with the tested torque which is working on guide pad.

• Journal of the Korean Society of Safety
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• v.25 no.5
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• pp.1-6
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• 2010

When the ceramic material is being machined, micro crack and brittle fracture dominate the process of material removal. Generally, ceramics are very difficult-to-cut materials and machined using conventional method such as grinding and polishing. However, such processes are generally cost-expensive and have low material removal rate. Machinable ceramics used in this study contain BN powder to overcome these problem and for productivity elevation. This paper focuses on machinability evaluation during end mill process with CNC machining center in this study. Experiment for this purpose is performed for tool wear patterns and mechanism.

• Proceedings of the Korean Society for Agricultural Machinery Conference
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• 2000.11b
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• pp.313-317
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• 2000

In this research, a grafting robot with plug in method is used. Plug in method is a method that uses a tapered axis for scion and a tapered hole for stock as processing style of conjugation parts. In the case of handling a grafting seedling, gripping a stem is doing with simple mechanisms of devising to reduce damages to stems. For example, providing cushions between gripper and stem, and fitting a gripper to a stem. Both scions and stocks need cutting, but there is bigger influence for scions than stocks, so problems of cutting scions and special qualities of grippers are necessary to investigate.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.1025-1028
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• 2002

In this paper, a micro-turning lathe is introduced for micro machining of aluminum rod. To give feed motion, stepwise motion[2] actuators are used instead of the conventional inchworm mechanism. These are consisted of two Piezoelectric ceramics; one is for feeding the slider, and the other is for clamping the slider in the guide way of the body. The guide is V-form. The linearity and positional accuracy of the actuators is good enough far high precision motion. Since the system is more compact than the conventional system using three Piezoelectric ceramics, it is applicable for the micro-machine or MEMS unit. To fabricate the lathe, a small spindle unit with ball bearings of diameter of 10 millimeter is built-up on the top the slider. The motion is feed backed with miniaturized linear encoder attached each axis slider. The diamond tool bite is used for cutting tool. The machining is tried to make small diameter rod. The possible diameter that can be machined in this machine is presented as well as chip formation, surface roughness, and machinability.