• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.2
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• pp.251-259
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• 2010

It is presented in this study a new efficient intelligent machining strategy, which can be used to remove the uncut volume at the boundary region of curved surfaces caused by cutter interference. The geometric form definitions and recognition of topological features of the surface triangulation mesh are used to generate cutter paths along successive and interconnected steepest pathways, that minimize the cusp height left after flat end milling. In order to machine the uncut volume gradually, the z-map cutter centers are adjusted to avoid cutter interference for the 6 kinds of avoidance types. And then, the generative subsequent paths are sequenced to determine the second step cutter paths for the next uncut volume. For the 2 kinds of test models with convex and concave surface region, the implemented software algorithm is evaluated by investigating the residual swelling of uncut volume for each machining step.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.1
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• pp.67-73
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• 2016

The application of titanium has been gradually rising because the utilizing ranges for low weight and high strength are rapidly increased by the need for improving the fuel economy in production industries such as the aviation and automotive in recent. The purpose in this study is to investigate the appropriate cutting conditions on the life of flat and round end mills by measuring the maximum cutting temperature relative to the machining time, and calculating the wear rates of cutting tool with the spindle speed and feed rate of vertical machining center as a parameter in the titanium roughing cut machining which is widely used in critical parts of aircraft, cars, etc. When the wetted roughing cut machining of titanium with a soluble cutting oil is conducted by the flat and round end mills, the maximum cutting temperatures for a variety of spindle speed and feed rate are measured at ten-minute intervals during 60 minutes by an infrared thermometer, and the wear rates of cutting tool are calculated by the weight ratios based on tool wear before and after the experiment. It is found that the maximum cutting temperature and the wear rates of cutting tool are raised as the cutting amount per tool edge is increased with the rise of feed rate, in this experimental range, and as the frictional area due to the rise of contacting friction numbers between tool and specimen is increased with the rises of cutting time and spindle speed. In addition, the increasing rate of maximum cutting temperature in the flat and round end mills are the highest for the cutting time from 50 to 60 minutes, and the wear rate of cutting tool in the flat end mill is 1.14 to 1.55 times higher than that in the round end mill for all experimental conditions.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.346-351
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• 2001

The technique of high speed machining is widely studied in machining field. Because the high efficiency and accuracy in machining can be obtained in high speed machining. Unfortunately the development of tool for high speed machining is not close behind that of machining tool. So in this study, we made 4 types flat end mill for obtaining data according to tool shape. Especially, we concentrated in helix angle and number of cutting edge. First we confirmed cutting condition by several experiments and measuring cutting force, tool life, tool wear and chip shape according to cutting length. In results, we acquired the fact that 45 degree helix angle and six cutting edge tool is suitable for high speed machining.

• 대한공업교육학회지
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• v.31 no.2
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• pp.350-363
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• 2006

Recently, the micro end-milling processing is demanded the high-precise technique with good surface roughness and rapid time in milli-structure parts, micro machine parts and molding industry. The cutting conditions of micro end-milling has an effect on surface roughness of cutting surface. Therefore this study was carried out to cut stainless steel using high revolution air bearing spindle and micro end-mill and analyze the cutting condition to get the optimum surface roughness by design of experiment. From this study, surface roughness have an much effect according to priority on depth of cut, revolution of spindle and feed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.7
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• pp.1095-1102
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• 2003

The most important thing in measuring the tool wear is to set up the measurement base. The end mill that is being used for machining of die is difficult to set up the base and to measure the tool wear because of geometric properties of that such as a helix and relief angle. In this study, a new instrument using spindle orientation function in end milling is developed to measure the tool wear and evaluated by the measuring system on the machine. Finally, this new method makes possible the wear measurement of same position and reduces the measuring time compared with the measuring methods such as the microscope and CCD.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.788-793
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• 1997

The surface,generated by end milling operation, is deteriorated by tool runout,vibration,friction,tool deflection, etc. In many source,deflection of tool affects to surfave accuracy. To develop a surface accracy model,method for the prediction of the topography of machined surfaces has been developed based on models of machine tool kinematics and cutting tool geometry. This model accounts for not only the ideal geometrical surface, but also the deflection of tool resulted in cutting force. For the more accurate prediction of cutting force,flexible end mill model is used to simulate cutting process. Compute simu;ation have shown the feasibility of the surface generation system.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.149-153
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• 2003

The most important thing in measuring the tool wear is to set up the measurement base. The end mill that is being used for machining is difficult to set up the base and to measure the tool wear because of geometric properties of that such as a helix and relief angle. In this study, a new instrument using spindle orientation function in end milling is developed to measure tool wear and evaluated by measuring system on the machine. Finally, this new method makes possible the wear measurement of same position and reduces measuring time compared with measuring methods such as the microscope and CCD.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.4
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• pp.498-503
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• 2010

The main purpose of this study strongly concerned micro machining error estimation by using FEM analysis of tool deflection shapes in micro flat end-milling process. For the precision micro flat end-milling process, analysis of micro cutting errors is mandatory. In general, tool deflection is a major factor which causes cutting error and limits realization of the high-precision cutting process. Especially, in micro end-milling process, micro tool deflection generates very serious problems in contrast to macro tool deflection. Methods which deal with compensation of cutting error by tool deflection in macro end-milling process have been studied plentifully but, few researches transact with micro scaled cutting tool deflection in micro cutting process. Therefore, the trend of micro tool deflection was estimated by using FEM analysis in this paper. Cutting forces were acquired by micro dynamometer and these were utilized in FEM analysis. In order to verify FEM analysis results, micro machining processes were carried out and real machined profiles were compared with FEM results. Finally through the proposed approach well suited FEM results were obtained.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.7
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• pp.62-69
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• 2004

This paper presents an experimental study on the dimensional error in ball-end milling. In the 3D free-formed surface machining using ball-end milling, while machining conditions are varied due to the Z component of the feed and existing hemisphere part of the ball-end mill, the mechanics of ball-end milling are complicated. In the finishing, most of cutting is performed the ball part of the cutter and the machined surface are required the high quality. But the dimensional errors in the ball-end milling are inevitably caused by tool deflection, tool wear, thermal effect and machine tool errors and so on. Among these factors, the most significant one of dimensional error is usually known as tool deflection. Tool deflection is related to the instantaneous horizontal cutting force and varied the finishing cutting path. It lead to decrease cutting area, thus resulting cutting forces but the dimensional precision surface could not be obtained. So the machining experiments are conducted fur dimensional error investigation and these results may be used for decrease dimensional errors in practice.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.3
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• pp.86-92
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• 2016

Mechanical milling, in association with electrical discharge machining (EDM) for hybrid machining, is presented in this paper. An end mill cutting tool, an electrode of the EDM, was used for the system. That means that some parts were cut by the mechanical cutting process and others by the EDM. The possibility of combining both processes was simulated with the cutting simulation software. In addition, the machining reality was verified by measuring the electrical signal from the EDM power supply, which was measured in time and frequency domains. From this initial research, the hybrid machining system proposed in this paper appears to be well suited for difficult to cut material processing.