• Journal of the Korean Society for Precision Engineering
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• v.19 no.10
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• pp.187-194
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• 2002

A study on machining electrode for LED (Light Emitted Diode) mold with shaped end-mill is presented. The electrode machining by shaped end-mill has been used for maximizing the productivity in manufacturing semiconductor mold. However, it has not been researched systematically for many difficulties such as the making of shaped end-mill, generation of tool path due to distinctive tool geometry, and so on. Tool path is generated on geometry of the shaped end-mill and cutting force to provide accurate and efficient machining of electrode. The verification program can drive enhancement of productivity, selecting cutting conditions from experiment function of cutting force. Also, compensation of tooling and maching error can make the electrode accurately by modifying tool path. Therefore, the research on machining with shaped end-mill can contribute to enhancement of accuracy and productivity in building semiconductor mold.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.8
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• pp.1287-1294
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• 2003

The wear process of end mill is so complicated process that a more reliable technique is required for the monitoring and controlling the tool life and its performance. This research presents a new tool wear monitoring method based on the sound signal generated on the machining. The experiment carried out continuous-side-milling for 4 cases using the high-speed-steel end mill under wet condition. The sound pressure was measured at 0.5m from the cutting zone by a dynamic microphone, and was analyzed at frequency domain. As the cutter impacts the workpiece surface, a situation of farced vibration arises in which the dominant forcing frequency is equal to the tooth passing frequency of the cutter. The tooth passing frequency appears as a harmonics form, and end mill flank wear is related with the first harmonic. It is possible to detect end . mill flank wear. This paper proposed the new method of the end mill wear detection.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.10
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• pp.27-33
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• 2019

The aviation industry has grown beyond the simple processing and assembling of aircraft parts and now designs and exports finished aircraft. In this study, the vertical CNC milling rotational speed and feed rate were parameters to investigate the life of tools according to their shape: (flat, round, and ball end mill) in the rough cutting of titanium. These tools are widely used in aircraft manufacturing and assembly. The purpose of this study is to measure the cutting temperature generated during the cutting process and calculate the rate of tool wear. This will be accomplished by measuring the tool weight before and after cutting the specimen and to compare it with the results of previous studies. Our study showed that the maximum cutting temperature increased as cutting time, tool rotational speed, and feed rate increased. The highest cutting temperatures were recorded for the ball, round, and flat end mill, respectively. Tool wear for the ball, round, and flat end mill increased as the speed and feed rate increased. The flat end mill exhibited the highest rate of wear from a minimum of 0.62% to a maximum of 2.88%.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.1
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• pp.57-65
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• 2021

With the increased utilization of CAM programs, end-mill processing is most commonly used for machining and metal processing. In particular, hole or shaft machining has high assembly precision, which inevitably leads to high utilization of end mills. However, the analysis of quality characteristics according to the process conditions of end mills is not performed systematically at the site, causing poor quality and productivity. The most influential factor of quality is the runout of the end mill. In this paper, the number of turns of the end mill, number of tool blades, cutting direction, and artificial runout volume were determined to identify the correlation between the epicenter, cylindricality, and surface roughness. Two types of end mills, three levels of runout, three levels of rotational speed, and two cutting directions were considered and 36 rounds of hole processing were conducted. For the analysis of shape characteristics according to the set process variables, the experimental planning method was applied to the measured specimen and the processing characteristics were analyzed according to the runout of the end mill through correlation analysis.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.176-181
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• 1994

As tools for machining precesion componants, end mills and ball end mill are widely used. For the end mill have longer cylindrical shape comparing diameter, they are liable to deflect when machining and induce geometrical error and deterioration of surface roughness. To improve the stiffness and the sharpness of the cutting edge of end mill, a software for manufaturing end mills are developed. The progeam predicts the result of helical flute grinding and the configuration of cutting edge which is located in cylindrical surface. Furthermore to facilitate the manufacturing end mill using CNC grinding machine, the setting conditions which satisfy the geometrical requirments like tool rake angle and stiffness are obtained.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.4
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• pp.223-229
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• 2003

Tool wear monitoring is an important technique in the flexible manufacturing system. This paper studies the end mill wear detection using CCD camera and pattern recognition method. When the end mill working in the machining center, the bottom edge of the end mill geometry change, this information is used. The CCD camera grab the new and worn tool geometry and the area of the tool geometry was compared. In this result, when the values of the subtract worn tool from new tool end in 200 pixels, it decides the tool life. This paper proposed the new method of the end mill wear detection.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.5
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• pp.395-401
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• 2014

Development of five axis tool grinding machine and CAD/CAM systems increase tool design flexibility. In this research, investigated are cutting characteristics of ball-end mill with different helix angle. Special WC ball-end mills with $0^{\circ}$, $10^{\circ}$, $20^{\circ}$, $30^{\circ}$ helix angles are designed and used in various cutting tests. Machining performance according to helix angle variation is evaluated from cutting forces, surface roughness, tool wear, produced chip shape, and vibration characteristics. The ball-end mill with $10^{\circ}$ helix angle shows the best cutting performance due to appropriate chip load distribution and smooth chip flow. This research can be used for cutting edge geometry optimization and novel design of ball-end mill.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.93-95
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• 2007

Studies on ski-end shape control at the top end of rolling plate in heavy thick plate mill by using FEM analysis and measuring system have been performed. Plate shape behaviour at the top-end on rolling by the two different methods in finishing rolling process has been observed. One is to minimize the height of ski-end by using pass line based on the relational model between shape factor and pick-up and the other one is to prevent turn down problem caused by the impact between table roller and down bended plate on rolling by using roll speed difference. To minimize the height of ski-end, the prediction models based on the FEM analysis and measuring data was developed. The control method of ski - end shape on finishing rolling process was applied in actual mill and the height of ski-end was reduced by about 50% compared with conventional operation.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.12
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• pp.143-152
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• 1997

The deflection of an end mill is very important in machining process and cutting simulation because it affects directly workpiece accuracy, cutting force, and chattering. In this study, the deflection of the end mill was studied both experimentally and by using finite element analysis. And the moment of inertia of cross sections of the helical end mill is calculated for the determination of the relation between geometry of radial cross section and rigidity of the tools. Using the Bernoulli-Euler beam theory and the concept of equivalent diameter, a deflection model is established, which includes most influences from tool geomety parameters. It was found that helix angle attenuates the rigidity of the end mill by the finite element analysis. As a result, the equivalent diameter is determined by tooth number, inscribed diameter ratio, cross sectional geometry and helix angle. Because the relation betweem equivalent diameter and each factor is nonlinear, neural network is used to decide the equivalent diameter. Input patterns and desired outputs for the neural network are obtained by FEM analysis in several case of end milling operations.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.15-19
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• 1996

The cusp height in ball end milling, flat end milling and filleted end milling according to various surface inclination angle was calculated. The calculation result shows that, for each kind of tools, there exists certain range of inclination angle in which cusp height characteristics favorable. From machining time calculation, filleted end mill found to be superior to flat end mill in rough machining of sculptured surface.