• Journal of Korea Multimedia Society
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• v.21 no.6
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• pp.649-658
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• 2018

In this paper, we propose a mechanical contact inner tap inspection system that can inspect the defect of the inner tap immediately after inner tap is processed within the machining center. The inspection module has the collet chuck structure, so it can mounted on the main spindle of the machining center during inspection. It was developed with a focus on inspection for tap having 20 mm depth which is primarily fabricated in automotive parts and has a double sided PCB-type control system including sensing function based on Zigbee module, micom and IR sensor for wireless transmission of measured data with low power operation, and also a battery for supplying electric power. The current consumption is 46.8mA in the inspection operation mode and 0.0268mA in the power saving mode for 3.7V of the applied power source, so that 30,000 times or more inspection can be performed with assumed 5 seconds inspection time for one tap. Experiments in test jig system and actual machining center confirm that the proposed inner tap inspection system can be applied to the batch process of simultaneous inspection after tapping in the machining center.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.4 no.4
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• pp.28-33
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• 2005

Recently, trends of TFT-LCD toward larger scale and thinner thickness continue. so, demands of Light Guide Panel (LGP) which is to substitute for prism sheet are appeared. Functions of LGP obtaining polarization of light of the prism sheet as well as the incidence and reflection of light are demanded. This prism type LGP to complete functions of the existing LGP and polarization at once must be supported by micro machining technology of LGP surface. In this research, the machining characteristics of the various materials were analysed by shaping using V-shaped single crystal diamond tool. The characteristics are machined surface, machining force due to the variation of cutting depth. Used specimens are engineering materials, which are 6:4 brass, oxygen-free copper, Al6061, PC, PMMA. The FFT analysis of the measured cutting force was conducted. The cutting characteristics were analyzed and the optimum cutting conditions with materials were established.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.6 no.3
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• pp.65-70
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• 2007

Generally, the core component of small precise optical device demands high accuracy of manufacturing processes. Although, the geometry of it is simple, the manufacturing technique to materialize is categorized as the ultra-precision machining and it must be done with the specialized machines and by the trained operator. Typical examples of small precise optical device are laser printer and phone camera. As a core part of laser printer, polygon mirror is used in laser scanning unit(LSU). It couldn't be fabricated with conventional machine but specified machine for polygon mirror machining. In this study, Polygon mirror with 16 surfaces was manufactured in the process of ultra-precision fly-cutting with Al material and investigated optimum machining conditions in terms of feedrate, pitch per cycle and depth of cut. Owing to process of polishing has bad influence on reflection angle, surface roughness, $R_{max}$=10nm, and form error, $Ra={\lambda}/10({\lambda}=632nm)$, are prerequisites for polygon mirror.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.547-552
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• 2003

In mold machining, there are many concave machining regions where chatter and tool deflection occur since MRR (material removal rate) increases as curvature increases even though cutting speed and depth of cut are constant. Boolean operation between stock and tool model is widely used to compute MRR in NC milling simulation. In finish cutting, the side step is reduced to about 0.3mm and tool path length is sometimes over 300m. so Boolean operation takes long computation time and includes much error if the resolution of stock and tool model is larger than the side step. In this paper, curvature of CL(cutter location) surface and side step of tool path is used to compute the feedrate for constant MRR machining. The data structure of CL surface is Z-map generated from NC tool path. The algorithm to get local curvature from discrete data was developed and applied to compute local curvature of CL surface. The side step of tool path was computed by point density map which includes cutter location point density at each grid element. The feedrate computed from curvature and side step is inserted to new tool path to regulate MRR. The resultants wire applied to feedrate optimization system which generates new tool path with feedrate from NC codes for finish cutting. The system was applied to speaker mold machining. The finishing time was reduced to 12.6%. tool wear was reduced from 2mm to 1.1mm and chatter marks and over cut on corner were removed.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.8
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• pp.929-935
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• 2011

As a deterministic finishing process for the optical parts having complex surface, machining performance of the magnetorheological(MR) fluid jet polishing of optical glass are studied and compared with a general water jet polishing. First, design of the jet polishing system which has the special electromagnet-nozzle unit for stabilizing the slurry jet based on MR fluid and the change of jet shape as magnetic field is applied are explained. Second, for the BK7 glass, machining spot and its cross section profile are analyzed and the unique effect of MR fluid jet polishing is shown. Third, both material removal depth and surface roughness are explored in order to investigate the polishing performance of MR fluid jet. With the same ceria abrasives and amount in the polishing slurries, MR fluid jet shows superior machining performance compared to water jet and the difference of material removal mechanism and its resulting performance are described.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.3
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• pp.101-106
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• 2002

This paper presents an experimental investigation of high speed machining of dies and molds. Several critical issues involved with the high speed machining of QRO90 tool steel of hardness up to HRc62, have been studied and explained from a detail analysis of experimental observations. The experiments were performed using ball end mills. The effect of different process parameters on tool life and surface finish produced was also investigated. The cutting parameters involved were; cutting speeds in the range of 100 to 40 / m/min, axial depth of cut from 0.1 to 0.5mm, pick feed of 0.1 to 0.5mm. Run out and acceleration signals were observed during the experiment to investigate cutting slates. Compressed air and flood coolant were used and the effect of coolant on tool life was also determined.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.775-778
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• 2000

Single point diamond turning technique fur optical crystals is reported in this paper. The main factors influencing the machined surface quality are discovered and regularities of machining process are drawn. Optical crystals have found more and more important applications in the field of modern optics. Optical crystals are mostly brittle materials of poor machinability. The traditional machining method is polishing which has many shortcomings such as low production efficiency, poor ability to be automatically controlled and edge effect of the workpiece. SPDT has been widely used in manufacturing optical reflectors of non-ferrous metals such as aluminum and copper which are easy to be machined for their proper ductility. But optical crystals being discussed here are characterized by their high brittleness which makes it difficult to obtain high quality optical surfaces on them. The purpose of cur research is to find the optimum machining conditions for ductile cutting of optical crystals and apply the SPDT technique to the manufacturing of ultra precision optical components of brittle materials. As a result, the cutting force is steady, the cutting force range is 0.05-0.08N. The surface roughness is good when spindle is above 1400rpm. and feed rate is small. The influence of depth of cut is very small.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.9
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• pp.1669-1680
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• 1992

This paper deals with the prediction of cutting force and tool deflection and it's application in the flexible ball end milling process. Machining accuracy is determined by the static stiffness of tool system and the instantaneous cutting force. The static stiffness of tool system consists of the stiffness of holer and the stiffness of ball end mill. The stiffness of holder was obtained from the experimental result, and the stiffness of ball end mill with two flutes was theoretically analyzed by the finite elements method. In cutting process, the instantaneous cutting force is dependent upon the instantaneous feed and pick feed(radial depth of cut) which are varied by tool deflection. For the calculation of cutting force and deflection of ball end mill, iteration method is used with the linear interpolation to the data of cutting force obtained from rigid ball end mill and the data of tool deflection. In this paper, a for enhancing accuracy is discussed. And the selection of helix angle for minimizing machining error is also discussed.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.6
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• pp.45-50
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• 2007

The aspheric lens has become the most popular optical component used in various optical devices such as digital cameras, pick-up lenses, printers, copiers etc. Using aspheric lenses not only miniaturizes and reduces the weight of products, but also lower prices and higher field angles can be realized. Additionally, plastic lenses are being changed to glass lenses more recently because of low accuracy, low acid-resistance and low thermal-resistance in the plastic lenses. Currently, one fabrication method of glass lenses is using a glass-mold method with a high precision mold core for mass production. In this paper, DOE (Design Of Experiments) and compensation machining were adopted to improve the surface roughness and the form accuracy of the mold core. The DOE has been done in order to discover the optimal grinding conditions which minimize the surface roughness with factors such as work spindle revolution, turbine spindle revolution, federate and cutting depth. And the compensation machining is used to generate high form accuracy of the mold core. From various experiments and analyses, we could obtain the best surface roughness 5 nm in Ra, form accuracy $0.167\;{\mu}m$ in PV.

• Journal of the Korean Society of Safety
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• v.24 no.1
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• pp.1-6
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• 2009

In machining of ceramic materials, they are very difficult-to cut materials because of there high strength and hardness. Machining of ceramics are characterized by cracking and brittle fracture. Generally, ceramics are machined using conventional method such as grinding and polishing. However these processes are generally costly and have low MRR(material removal rate). This paper focuses on machinability evaluation of machinable ceramics for products with CNC machining center. Thus, in this paper, experiment applying cutting parameters is performed based on experimental design method. A design and analysis of experiments is conducted to study the effects of these parameters on the surface roughness by using the S/N ratio, analysis of ANOVA, and F-test. And multiple linear regression analysis is applied to compare experimental with predicted data in consideration of surface roughness. Cutting parameters, namely, feed, cutting speed and depth of cut are used to accomplish purpose of this paper. Required experiments are performed, and the results are investigated.