• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.21 no.3
• /
• pp.22-28
• /
• 2022

In the semiconductor and display component industries, the use of ceramic materials, which are high-strength materials, is increasing for ensuring durability and wear resistance. Among them, alumina materials are used increasingly. Alumina materials are extremely difficult to process because of their high strength; as such, research and development in the area of mineral material processing is being promoted actively to improve their processing. In this study, the processability of an electrodeposition tool is investigated using the electrodeposition method to smoothly process alumina materials. Furthermore, processing is conducted under various processing conditions, such as spindle speed, feed speed, and depth of cut. In addition, the processing characteristics of the workpiece are analyzed based on the tooling.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2009.10a
• /
• pp.667-668
• /
• 2009

• Design & Manufacturing
• /
• v.6 no.1
• /
• pp.24-28
• /
• 2012

Friction and wear affect all processes involved in the extraction of materials and their conversion into finished products in the die applications such as drawing, extrusion etc. Originating phenomenon from the contact surface between the tool and workpiece, they are usually a hindrance to materials process operations which usually result in damaging the tools, increasing energy consumption, the contamination of processed material by wear particles and also some problems associated with technologies to control friction and wear. The most well established method to control friction and wear is by the application of lubricant such as fluorocarbon. Besides, a surface technique so-called surface modification can be applied to solve the tribology problems of the die applications for both the economical and ecological reasons. In this article, we applied DLC(diamond-like carbon) thin film on alumina ceramic for HT test using the PIID(plasma ion immersion deposition), 4 groups of test specimens were tested up to $200^{\circ}C$ which is a little higher than the normal working temperature of die application. Pin-on-disc tribo-tester was used to test the friction and surfaces were characterized by SEM and EDS and else, the morphology changes of DLC coatings were studied. The present work indicated that the DLC had a great potential to reduce the friction and wear in the alumina die application without lubricants.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2001.04a
• /
• pp.101-106
• /
• 2001

In order to establish the optimum process parameters and diamond saw blade composition for machining natural stone, the chip formation process and the wear process must be understood. Diamond saw blade is one of the most effective, versatile, and extensively used methods of processing rock and other hard materials, such as granite, marble, concrete and asphalt. For many years, it has been known that chip thickness is one of the most significant in the understanding of the sawing process, and other variables such as force and power have been correlated with it. In this study, mathematical relations of a material chipped by a single grit of the saw blade will be undertaken. The material chipping geometries have been mathematically defined and derived as maximum chip thickness.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.36 no.6
• /
• pp.591-598
• /
• 2012

In this study, the cutting characteristics of bulk metallic glass (BMG) cut using a computer numerically controlled (CNC) lathe were investigated for different insert tool materials and cutting speeds. The surface roughness, chip morphology, cutting forces, and tool wear during turning of $Zr_{50}Cu_{40}Al_{10}$ BMG alloy were examined. Four kinds of tool materials were used to cut an 8-mm-diameter BMG. The examination of the surface roughnesses of the BMG specimens machined at each cutting speed showed that the surface roughness became better as the cutting speed increased, and the tool materials also influenced the surface roughness. The chip morphology investigations showed that the unoxidized BMG chips had serrated curled chips with adiabatic shear bands, while the oxidized chips exhibited local melting and tangling rather than the usual spiral-shaped chips. The cutting force induced during machining of the Zr-based BMG was the largest for the TiN-WC tool, followed by the polycrystalline diamond (PCD) tool. The cermet tool exerted the smallest cutting force.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2001.10a
• /
• pp.355-359
• /
• 2001

In this study, experiments were carried out to investigate the characteristics of grinding and wear process of diamond wheel grinding ceramic materials. Normal component of grinding resistance of $AI_2O_3$ was less then that of $Si_3N_4$ and $ZrO_2$. It is because the resistance for grain shedding is less then that for layer formation. For the case of $Si_3N_4$ and $ZrO_2$, as the grain mesh number of wheel increases, the surface roughness decreases. For the case of $AI_2O_3$, the surface roughness does not decreases. For the case of $Si_3N_4$ and $ZrO_2$, grinding is carried out by abrasive wear processes. For the case of $AI_2O_3$, grinding is carried out by grain shedding process.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.16 no.6
• /
• pp.1-6
• /
• 2017

Recently, the brittle materials such as ceramics, glass, sapphire and textile material have been widely used in semiconductors, aerospace and automobile owing to high functional characteristics. On the other hand, it has the characteristics of difficult-to-cut material relative to all materials. In this study, diamond electro-deposited band-saw machine was developed to operate stably using water-coolant type through relative motion between band-saw tool and $Al_2O_3$ material. High densified $Al_2O_3$ material was manufactured by spark plasma sintering method. The bulk density was observed by the Archimedes law and the theoretical density was estimated to be $3.88g/cm^3$ and its hardness 14.7 MPa. From the dicing sawing test of $Al_2O_3$ specimen, behavior of surface roughness and band-saw wear are dominantly affected by the increase of the band-saw linear velocity. Additionally, an continuous pattern type of diamond band-saw was a very effective due to entry impact as a one-off for brittle material.

• Advances in materials Research
• /
• v.1 no.2
• /
• pp.129-146
• /
• 2012

Polycrystalline diamond is an ideal material for parts with micro-holes and has been widely used as dies and cutting tools in automotive, aerospace and woodworking industries due to its superior wear and corrosion resistance. In this research paper, the modeling and simultaneous optimization of multiple performance characteristics such as material removal rate and surface roughness of polycrystalline diamond (PCD) with ultrasonic machining process has been presented. The fuzzy logic and taguchi's quality loss function has been used. In recent years, fuzzy logic has been used in manufacturing engineering for modeling and monitoring. Also the effect of controllable machining parameters like type of abrasive slurry, their size and concentration, nature of tool material and the power rating of the machine has been determined by applying the single objective and multi-objective optimization techniques. The analysis of results has been done using the MATLAB 7.5 software and results obtained are validated by conducting the confirmation experiments. The results show the considerable improvement in S/N ratio as compared to initial cutting conditions. The surface roughness of machined surface has been measured by using the Perthometer (M4Pi, Mahr Germany).

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.12 no.4
• /
• pp.9-16
• /
• 2003

In this study, the decision of dressing time for diamond wheel was analyzed by observing with acoustic emission signals and surface roughness, and also obtained the machining characteristics by weibull distribution plot for the values of bending strength. From the experimental study, it was possible to predict the time of re-dressing for the diamond grinding wheel with the analysis of acoustic emission signals and surface roughness values, and following conclusions were obtained. The root-mem-square values of acoustic emission signals were obtained low as the increased of table speed for different abrasive grain size. This is caused by the lack of grinding power which is not able to get rid of all real grinding mass of depth as the table speed is increased. The values of bending strength for ground $Si_3 N_4$ specimens were decreased for gain size of #400 than that of #60, but it was found that the surface roughness values for gain size of #60 were better than that of #400. As compared the shape parameter of weibull distribution plot for the values of bending strength, it was found that the reliability of bending strength for grain size of #60 increased than that of #400.

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.11 no.3
• /
• pp.86-92
• /
• 2002

In this study, experiments were carried out to investigate the characteristics of grinding and wear process of diamond wheel far ceramic materials. Normal component of grinding resistance of $Al_2$O$_3$ was less then that of $Si_3 N_4$ and $ZrO_2$. This seems to be the characteristics of ceramic tools on work pieces both of high hardness. For the case of $Si_3 N_4$ and $ZrO_2$, as the mesh number of wheel increases, the surface roughness decreases. For the case of $Al_2 O_3$, the surface roughness does not decreases. Specific binding energy decreases as the material removal rate per unit time increases. For the case of $Si_3 N_4$ and $ZrO_2$, grinding is carried out by abrasive wear processes. For the case of $Al_2 O_3$, grinding is carried out by grain shedding process due to brittle fracture.