• Journal of the Korean Professional Engineers Association
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• v.34 no.2
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• pp.10-13
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• 2001

Workpiece materials may be relatively easy to machine by traditional methods but workpiece geometry also may be a constraint. Many shapes that are geometrically difficult to handle conventionally may be candidates for nontraditional processes. Nontraditional processes provide new opportunities for product design innovation and productivity improvements. Difficult-to-machine materials of geometric shapes difficult o produce with traditional equipment and tooling, may often be easily and cost effectively machined using nontraditional processes. Notraditional machining processes are relative newcomers o the manufacturing arena. Nontraditional chemical solutions, or even electrolytic current as the working medium rather than a conventional cutting tool or abrasive to remove or shape materials.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.6
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• pp.158-163
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• 2000

High speed machining of difficult-to-cut materials generates the concentrated thermal/frictional damage at the cutting edge of the tool and rapidly decreases the tool life. In this paper, the cutting environments, such as dry, fluid coolant, and compressed chilly air coolant, were investigated to improve the tool life. For this study, the compressed chilly air system was manufactured. The experiments were performed for various difficult-to-cut materials and various coated tools. The effectiveness of the developed methods on the basis of tool life was estimated. The results show that the cutting environment using compressed chilly air coolant provided better tool life than using the fluid coolant or using the dry.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.12
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• pp.2172-2178
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• 1997

Development of diamond wheel with fine grains and multi-pore structures were newely attempted. Wheels, that are employed for ultra precision and high performance grinding of difficult-to materials such as tungsten carbide alloy using tool and die materials, must have both performances to remove tool marks efficiently and to contact elastically with curved surfaces. Diamond grains were bonded firmly by a melamine resin to prevent the decrease of machining efficiency due to grain sinking within the bond materials. Also, highly foamed structures were developed to increase the flexibility of the wheel, and to induce active self-sharpening by increasing contact pressure between the wheel and work surfaces. In this paper, melamine-bonded diamond wheels are trial manufactured, then the forming method of wheels are suggested, and the grinding characteristics of wheels are also illustrated.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.1
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• pp.29-33
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• 2014

Recently, Difficult-to-cut materials are used in many manufacturing industry. But the difficult-to-cut materials are difficult-to-cutting process. So difficult to cut material cutting process was used after heat treatment through preheating for easy cutting process. In this study, Inconel 625 was preheating using laser heat source in computer simulation. Laser heat source temperature applied $1290^{\circ}C$ that suitable preheating temperature for Inconel 625. And temperature effects such as temperature distribution for moving heat source studied apply to similar actual process condition. Simulation results for heat treatment effects through temperature distribution verified.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.1101-1104
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• 2001

The special purposed materials, such as ceramics and stainless steel, are widely used in the various industrial area. They have properties of the higher strength of material, the wear-resistance, and the corrosion proof. But ceramics is a difficult-to-grind material which possesses the higher level of a strength and a brittleness. In this study, the theoretical investigation of a grinding force and of a surface roughness was conducted. The evaluations of grinding characteristics on the hardened-brittle and difficult-to-grind materials were experimentally carried out.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.118-123
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• 1995

A new grindignwheel was developed for the high performance gfinding of difficult-to-grind materials. Te grinding performance (such as grinding forces, grinding ratio, and surface roughness of ground surface) of the newly developed wheel was evaluated through experiments. Experimental results show that the performance of the newly developed wheel is superior to conventional alumina wheel and comparable to the S-G wheel.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.359-364
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• 1999

Due to rapid growth of die and mould industries, it is urgently required to maximize the productivity and the efficiency of machining. In recent years, owing to the development of new kinds of material, die and mould materials are much harder and it is more difficult to cut. In this study, the workpiece SKD11(HRC45) is cut with TiAlN coated tungsten-carbide cutting tools. To find the general characteristics of difficult-to-cut materials, orthogonal turning test is performed. Orthogonal cutting theory can be expanded to oblique cutting model. The oblique cutting process in the small cutting edge element has been analyzed as orthogonal cutting process in the plane containing the cutting velocity vector and chip-flow vector. Hence, with the orthogonal cutting data obtained from orthogonal turning test, the cutting forces can be analyzed through oblique cutting model. The simulation results have shown a fairy good agreement with the test results.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.2
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• pp.100-107
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• 1998

Diamond wheels with fine grains and multi-porous structures are newely trial developed for smoothing and mirror finishing materials. Grinding wheel must have performed both to remove tool marks efficienitly and to contact elastically with curved surfaces, that are employed for ultra precision and high performance grinding of difficult-to materials such as tungsten carbide alloy using tool and die materials, Diamond grains are bonded by a melamine resin to prevent the decrease of machining efficiency due to grain sinking within the bond materials. Also, highly foamed structures are developed to increase the flexibility of the grinding wheel, and to induce self-sharpening by increasing contact pressure between the grinding wheel and workpiece surfaces. In this paper, melamine-bonded diamond wheels try to manufacture, then the forming method of grinding wheel are suggested, and the grinding characteristics of melamine-bonded diamond grinding wheel are also illustrated.

• Korean Journal of Materials Research
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• v.30 no.12
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• pp.672-677
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• 2020

Expensive PCBN or ceramic cutting tools are used for the processing of difficult-to-cut materials such as Ti and Ni alloy materials. These tools have a problem of breaking easily due to their high hardness but low fracture toughness. To solve this problem, cutting tools that form various coating layers are used in low-cost WC-Co hard material tools, and researches on various tool materials are being conducted. In this study, WC-5, 10, and 15 wt%Ni hard materials for difficult-to-cut cutting materials are densified using horizontal ball milled WC-Ni powders and pulsed current activated sintering method (PCAS method). Each PCASed WC-Ni hard materials are almost completely dense, with a relative density of up to 99.7 ~ 99.9 %, after the simultaneous application of pressure of 60 MPa and electric current for 2 min; process involves almost no change in the grain size. The average grain sizes of WC and Ni for WC-5, 10, and 15 wt%Ni hard materials are about 1.09 ~ 1.29 and 0.31 ~ 0.51 µm, respectively. Vickers hardness and fracture toughness of WC-5, 10, and 15 wt%Ni hard materials are about 1,923 ~ 1,788 kg/mm2 and 13.2 ~ 14.3 MPa.m1/2, respectively. Microstructure and phase analyses of PCASed WC-Ni hard materials are performed.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.1
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• pp.94-100
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• 2010

Nowadays, several nontraditional machining(NTM) processes are widely used to machine a complex and accurate shape part of hard materials, such as titanium, ceramics, high strength temperature resistant and refractory materials which are difficult to machine and having high strength, hardness, toughness. Machining of these complex shapes in such materials by traditional machining processes are very difficult. The NTM processes is important in the areas of micro- and nano scale machining, where high accuracy and superior surface characteristics are required, which can only be achieved using these NTM processes. So, for effective selection of different NTM processes, careful decision making for a given NTM application is often necessary. An appropriate NTM process for a given material and shape condition is very difficult for the novice engineers. In this paper, an expert system based on an analytic network process(ANP) is suggested for a best selection of NTM process in a NTM application considering an prior interdependency effect among various factors.