• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.6
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• pp.65-70
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• 2000

Although the net-shape molding of composites is generally recommended, molded composites frequently requires cutting or grinding due to the dimensional inaccuracy for precision machine elements. During the composite machining operations such as cutting and grinding, the temperature at the grinding area may increase beyond the allowed limit due to the low thermal conductivity of composites, which might degrade the matrix of composite. Therefore, in this work, the temperature at the grinding point during surface grinding of carbon fiber epoxy composite was measured. The grinding temperature and surface roughness were also measured to investigate the surface grinding characteristics of the composites. The experiments were performed both under dry and wet grinding conditions with respect to cutting speed, feed speed, depth of cut and stacking angle. From the experimental investigation, the optimal conditions for the composite surface grinding were suggested.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09b
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• pp.875-876
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• 2006

For dry machining of mineral materials the Institute of Materials Engineering pursues a novel thermal protection shield concept for diamond tools, in which thermal insulating materials in diamond composite structures act as heat shield, which protects diamonds in deeper layers against high temperature and graphitisation. Before the effectiveness of this concept could be investigated suitable composites have to be manufactured. In this paper the powder metallurgical production processes of diamond-alumina-cobalt-composites with varying alumina and cobalt particle sizes, their microstructures and porosities are described. It could be observed that the distribution of small-sized alumina particles ($<70{\mu}m$) in the cobalt matrix is uniform and the porosity of the composite decrease.

• Journal of Korean Society of Occupational and Environmental Hygiene
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• v.15 no.3
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• pp.166-175
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• 2005

Health effects associated with metal working fluid (MWF) exposures include dermatitis, respiratory disease, hypersensitive pneumonitis, and asthma. Frequently, occupational exposures to MWFs are controlled by ventilating an enclosure with an air cleaning unit that includes a fan preceded by various kinds of filtration. There are several kinds of air cleaning units used in machining centers. But the associated troubles have hindered from efficiently using these devices. The main problem is the relatively short period of filter replacement. The reason is that the air cleaning units usually do not have the de-oiling systems, thus leading the earlier clogging of filters and reducing the flow rate of hood. Thus, the first stage of study was conducted to overcome this problem by developing the new oil mist collector equipped with the easy de-oiling system. The principle of de-oiling is that the centrifugal force generated by spinning the drum covered by filter fabric separates oils from the filter fabric. It would be very similar to the spin-dry laundry. By adopting this de-oiling technique, the problems associated with the conventional oil mist collectors could be solved. Several tests/analyses were performed to make the lab-scale oil mist collector. The collection efficiencies and the de-oiling efficiencies of commercially available filter fabrics were tested. Subsequently, the endurance test were conducted by observing SEM photos of filter fabrics and measuring tensile strength/expansion coefficient after spinning the filter drum for 20 minutes at the different rotation speeds. By doing these experiments, the most appropriate filter fabric and rotation speed/duration were selected. Finally, the new oil mist collector was designed. In the near future, this device must be tested in the real machining center.

• Steel and Composite Structures
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• v.34 no.5
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• pp.681-698
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• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.

• Journal of the Korea Furniture Society
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• v.19 no.6
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• pp.411-419
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• 2008

Xylia xylocarpa is fast-growing trees that are currently planted on trial basis in Sabah, Malaysia. The wood quality of trees grown in Sabah may differ from those grown in other places due to the environmental factors. Five 9-year-old trees of each species were extracted from their respective plots at Luasong, Tawau. Wood specimens were prepared from three height levels; bottom, middle and top, at the inner and outer radial positions. The within-tree and between-tree variations of physical properties of these species were analyzed. The basic density, oven-dry density and green moisture content(MC) are 0.72g/$cm^3$, 0.78g/$cm^3$ and 49.8% respectively. The shrinkage from green to oven-dry conditions for the radial and tangential directions were 3.35% and 5.76%, respectively. The trends of within-tree variations for most properties were more consistent in radial rather than vertical direction. This suggests diameter growth to be a more important factor contributing to the variations compared to height. Samples from the outer part of the stem were found to have higher density, shrinkage and mechanical strengths. The between-trees variations of some wood properties were found to be significantly different, probably due to genetic and micro-environmental factors. Significant correlation was recorded among the physical properties of the species. The true potential of X. xylocarpa for end-uses would be enhanced by further research such as the study on properties of wood from different sites and other properties like durability, seasoning, processing and machining characteristics. The characteristics of X. xylocarpa are comparable to a number of local popular hardwood species, indicating its suitability for heavy construction uses.

• International Journal of Precision Engineering and Manufacturing-Green Technology
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• v.5 no.5
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• pp.583-591
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• 2018

Tool-chip adhesion impacts on cutting performance significantly, especially in finish cutting process. To promote cutting tools' anti-adhesion property, the concave micro-grooves texture (MGT) and convex volcano-like texture (VLT) were fabricated separately on lathe tools' rake faces by laser surface texturing (LST). Various orientations of MGT and different area densities (9% and 48%) and regions (partial and full) of VLT were considered in textured patterns designing. The following orthogonal cutting experiments, machining of aluminum alloy 5038, analyzed tools' performances including cutting force, cutting stability, chip shape, rake face adhesion and abrasion. It indicated that under dry finish cutting conditions, MGT contributed to cutting stability and low cutting forces, meanwhile friction and normal force reduced by around 15% and 10%, respectively with a weak correlation to the grooves' orientation. High density VLT tools, on the other hand, presented an obvious anti-adhesion property. A $5{\mu}m$ reduction of crater wear's depth can be observed on textured rake faces after long length cutting and textured rake faces presented half size of BUE regions comparing to the flat tool, however, once the texture morphologies were filled or worn, the anti-adhesion effect could be invalid. The bearing ratio curve was employed to analysis tool-chip contact and durability of textured surfaces contributing to a better understanding of anti-adhesion and enhanced durability of the textured tools.

• Structural Engineering and Mechanics
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• v.84 no.1
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• pp.17-33
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• 2022

An experimental study is carried out to investigate the performance of the cutting tool regarding the insert wear, surface roughness, cutting forces, cutting power and material removal rate of three coated carbides GC2015 (TiCN-Al₂O₃-TiN), GC4215 (Al₂O₃-Ti(C,N)) and GC1015 (TiN) during the dry turning of AISI4140 steel. For this purpose, a Taguchi design (L₉) was adopted for the planning of the experiments, the effects of cutting parameters on the surface roughness (R_a), tangential cutting force (F_z), the cutting power (P_c) and the material removal rate (MRR) were studied using analysis of variance (ANOVA), the response surface methodology (RSM) was used for mathematical modeling, with which linear mathematical models were developed for forecasting of R_a, F_z, P_c and MRR as a function of cutting parameters (V_c, f, and a_p). Then, Multi-Objective Ant Lion Optimizer (MOALO) has been implemented for multi-objective optimization which allows manufacturers to enhance the production performances of the machined parts. Furthermore, in order to characterize and quantify the flank wear of the tested tools, some machining experiments were performed for 5 minutes of turning under a depth of 0.5 mm, a feed rate of 0.08 mm/rev, and a cutting speed of 350 m/min. The wear results led to a ratio (V_B-GC4215/V_B-GC2015) of 2.03 and (V_B-GC1015/V_B-GC2015) of 4.43, thus demonstrating the efficiency of the cutting insert GC2015. Moreover, SEM analysis shows the main wear mechanisms represented by abrasion, adhesion and chipping.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.2 s.173
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• pp.338-346
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• 2000

Although the net-shape molding of composites is generally recommended, molded composites are frequently required cutting or grinding due to the dimensional inaccuracy for precision machine elements . During the composite machining operations such as cutting and grinding, the temperature at the cutting point may increase beyond the allowed limit due to the low thermal conductivity of composites, which might degrade the matrix of composite. Therefore, in this work, the temperature at the cutting point during cut-off grinding of carbon fiber epoxy composites was measured. The cutting force and surface roughness were also measured to investigate the cut-off grinding characteristics of the composites. The experiments were performed both under dry and wet grinding conditions with respect to cutting speed and feed rate. From the experimental investigation, the optimal conditions for the composite cut-off grinding were suggested.

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.968-973
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• 2003

As environmental restrictions have continuously become more strict, it has emphasized development of environment-friendly technologies. In cutting technology, it has been well recognized that cutting fluids might have undesirable effects on worker's health and working environment and, hence, recently there have been numerous attempts to minimize harmful effects of cutting fluids on environments. To minimize the use of cutting fluids in machining, conventional cutting fluids have been replaced with the technologies of pressurized cold air and minimum quantity lubrication(MQL). Compared with milling, turning is a continuous cutting process, where tools are continuously heated up and lack of lubricity could lead to tool wear and deteriorated surface roughness. In this study, it has been investigated how tool wear and surface roughness could be affected by cutting conditions, supply and cooling methods. The experimental results show that MQL technology is able to minimize harmful effects of conventional cutting fluids.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.2
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• pp.223-227
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• 2013

Dust collecting performance of cyclone collector for oil mist was alalyzed in the study. The purposes of using cutting fluid during cutting have been colling, lubricating, chip washing and anti-corroding. However, the present manufactaring industry restricts the use of cutting fluid because cutting fluid confains poisonous substances which are harmful to the human body. Also, the optimum design oil-mist collector. The new oil mist collector was designed. In the near future, this device must be tested in the real machining center and CNC machine. Cutting using oil-mist showed better cutting characteristics than dry, air and fluid cutting with respect to by cutting force, tool wear and surface roughness. The model(A, B Type cyclone) of the set of fixture and alveolus are made by using a CAE software. Finally, we have obtained a model A Type solution by using orthogonal array. Therefore, it could be confirmed that as the model-A was increased and model-B was decreased, cut diameter was decreased.