• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.17 no.4
• /
• pp.95-103
• /
• 2008

Diamond core drills are applied to drill difficult-to-cut materials. This paper proposes basic understanding of ceramic drilling mechanics and characteristics of main factors affecting tool life, tool wear, cutting force, and chipping thickness. In contrast to conventional drilling, the core drilling process make deep grooves on the workpiece. One difficulty of it is the evacuation of chips from the drilled groove. As the drilling depth increases, an increased amount of chips tend to cluster together and clog the groove. Eventually severe wear develops and diamond grits are separated from the drill body. To relieve the clogging problem and to evacuate chips from the groove easily, the helical drilling process is applied for the core drilling process. To analyze drilling characteristics and derive optimal drilling conditions, tool life, tool wear, cutting force, and chipping thickness are quantified through the monitoring system and the Taguchi method. Mathematical models for the tool life and chipping thickness are derived from the response surface method. Optimal drilling database has been constructed through the experimental models.

• International Journal of Precision Engineering and Manufacturing
• /
• v.6 no.1
• /
• pp.65-72
• /
• 2005

Drilling process is one of the most common, yet complex operations among manufacturing processes. The performance of a drill is largely dependent upon drilling forces, Many researches focused on the effects of drill parameters on drilling forces. In this paper, an effective theoretical model to predict thrust and torque in drilling is presented. Also, with the predicted forces, the stress analysis of the drill tool is performed by the finite element method. The model uses the oblique cutting model for the cutting lips and the orthogonal cutting model for the chisel edge. Thrust and torque are calculated analytically without resorting to any drilling experiment, only by tool geometry, cutting conditions and material properties. The stress analysis is performed by the commercial FEM program ANSYS. The geometric modeling and the mesh generation of a twist drill are performed automatically. From the study, the effects of the variation of the geometric features of the drill and of the cutting conditions of the drilling on the drilling forces and the stress distributions in the tool are calculated analytically, which can be applicable for designing optimal drill geometry and for improving the drilling process.

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.10 no.2
• /
• pp.10-17
• /
• 2001

Drilling is one of the most important operations performed in the machining industry. And the material of the workpiece has a profound effect on the tool life, the surface finish produced and the overall economy of the process. Hot-rolled high strength steels have been used for automobile structural material, owing to high hardness and machinability of the material. However, in the drilling of hot-rolled high strength steels, the current knowledge of tool wear and machinability are insuf-ficient. There, it is desirable to monitor drill wear status and hole quality changes during the hole drilling process. Accordingly, this paper deals with the cutting characteristics of the hot-rolled high strength steels using common HSS drill. The performance variables include the drilling thrust, torque and drill wear data obtained from drilling experiments con-ducted on the workpiece. Also drill were is measured by acoustic emission system and computer vision system.

• Journal of Power System Engineering
• /
• v.5 no.3
• /
• pp.73-79
• /
• 2001

The purpose of this investigation is experimentally to clarify the machinability and tool wear of STS 304 steel pipe material for piping. In order to determine the effects of cutting parameters and tool wear on thrust, torque, AE RMS, drilling is conducted on CNC milling machine. In this experiment, it is measured that thrust, torque, tool wear length, tool wear area and AE RMS during drilling using Hss tool. It has been found that a) During the drilling, the thrust and the torque of the STS 304 pipe are received more the effect of the feed than the spindle speed and the thrust increase with the increase of feed, b) The value of the AE RMS is been larger the effect of the cutting speed than the feed rate, and the value of the AE RMS increase with the increase of spindle speed, c) It has been found that the suitable feed in feed condition of 0.03, 0.05, 0.1, 0.15mm/rev is below 0.05mm/rev, d) The value of the AE RMS was shown a characteristic of the jump value during it was a sudden inrcrease of the tool wear. The increased character of the AE RMS value can be known an effective factor of the tool wear detection, and e) It can be quantitatively evaluated the condition of the tool according to calculate a area of the drill wear image which is obtained by a vision system.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.16 no.4
• /
• pp.83-88
• /
• 2017

Recently, the use of advanced materials with light weight significantly increases because of global regulation on CO2 emission. Especially, CFRP (carbon fiber reinforced plastics) one of the most promising advanced materials. Since CFRP has pretty higher strength per unit weight than steel, it is one of most popular materials in aviation industry and its application to automobile rises sharply. Especially, one of the frequent machining processes for CFRP is drilling to make a hole, however, CFRP drilling has troublesome limitations in hole quality and productivity induced due to delamination, splintering and severe tool wear. Particularly, cutting loads increase caused by tool wear makes delamination and splintering even severer. Therefore, tool wear monitoring or reduction in CFRP drilling must be considered seriously. In this study, we measured thrust force, flank wear, and tool surface temperature in drilling using various tools with different sizes and materials. Consequently, it was presented the effects of tool properties on drilled hole quality, thrust force and tool surface temperature.

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.13 no.3
• /
• pp.133-140
• /
• 2004

Recently reduction of industrial products in size and weight has been increased by application of micro-drills in gadgets of high precision and a great interest of a micro-drilling has been raised. Due to the lack of tool stiffness and the chip packing, the micro-drilling requires not only the robust tool structure which has not affected by vibration but also effective drilling methods designed to prevent tool fracture from cutting troubles. This paper presents an optimum design shape of a 0.15 mm micro-drill associated with a new manufacturing process to improve the production rate and to lengthen the tool life and suggestions on the micro-drilling characteristic properties associated with the tool life and workpiece quality.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2001.04a
• /
• pp.287-293
• /
• 2001

Resently, reduction of industrial products in size and weight has increased by the application of micro-drill for gadgets of high precision and gave rise to a great interest in a micro-drilling. Due to the lack of tool stiffness and the chip Packing, micro-drilling requires not only the robust tool structure which has not affected by the vibration, but also the effective drilling methods designed to prevent tool fracture from cutting troubles. Firstly, this paper presents a new manufacturing process of micro-drill for improving the Product rate and an optimum shape of micro-drill for lengthening the tool life, and secondly between tool life and drilling torque acquired in the inprocess monitoring system.

• 제어로봇시스템학회:학술대회논문집
• /
• 2003.10a
• /
• pp.264-268
• /
• 2003

Recently reduction of industrial products in size and weight has been increased by application of micro-drills in gadgets of high precision and a great interest of a micro-drilling has been raised. Due to the lack of tool stiffness and the chip packing, the micro-drilling requires not only the robust tool structure which has not affected by vibration but also effective drilling methods designed to prevent tool fracture from cutting troubles. This paper presents an optimum design shape of a 0.15 mm micro-drill associated with a new manufacturing process to improve the production rate and to lengthen the tool life and suggestions on the micro-drilling characteristic properties associated with the tool life and workpiece quality.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.1 no.1
• /
• pp.109-116
• /
• 2002

Resently, reduction of industrial products in size and weight has increased by the application of micro-drill for gadgets of high precision and gave rise to a great interest in a micro-drilling. Due to the lack of tool stiffness and the chip packing, micro-drilling requires not only the robust tool structure which has not affected by the vibration, but also the effective drilling methods designed to prevent tool fracture from cutting troubles. Firstly, this paper presents a new manufacturing process of micro-drill for improving the product rate and an optimum shape of micro-drill for lengthening the tool life, and secondly suggests between tool life and drilling torque acquired in the inprocess monitoring system.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.26 no.6
• /
• pp.1120-1126
• /
• 2002

Machining characteristics of tool steels manufactured by electro slag casting process has been investigated in this study. For the estimation of machinability, turning and drilling tests are carried out. The chip shapes at various velocities are investigated for the comparison of turning workabilities of tool steels because the chip shapes reflect characteristics of cutting resistance. In case of drilling test, feed motor currents measured by a hall sensor are used as a measure for the drilling resistance. The machining characteristics of the tool steels are strongly correlated with tensile properties, such as tensile strength, hardness, and ductility. In case of turning workability, it was found to be favoured by the higher tensile strength, while the opposite is true far the drilling workability. The electro-slag casted materials show better turning workability in the viewpoint of chip shapes and, the quenching-tempered electro-slag casted material has relatively better drilling machinability than that of the annealed one.