• Journal of the Korean Society for Precision Engineering
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• v.24 no.10
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• pp.37-45
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• 2007

End-milling is intermittent cutting process performed by a tool with a number of teeth. Its cutting forces are commonly measured by the tool dynamometer which has rectangular coordinates. In this case, the pattern of cutting forces is different according to cutting conditions. At a certain cutting condition, the sign of cutting force changes from positive to negative during a revolution of one tooth. The change of force direction excites a cutting tool and severe vibration arises when radial depth of cut increases. In this study, cutting experiments and simulations were carried out in order to explain the cause of the change of the cutting force direction. In addition, the effect of the cutting force change was discussed in terms of chatter vibration in end milling.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1998.03a
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• pp.30-34
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• 1998

In-process monitoring of cutting conditions and tool wear is important for improving productivity. This paper is concerned with on-line monitoring of tool wear and cutting force in end milling operation. The experimental study deals with the relations between flank wear and cutting force signal. Tool wear is detected by monitoring of cutting signal. A monitoring procedure is shown in this paper. The influence of flank wear on cutting signal activity was examined. The results are presented in the form of graphs. The analysis of the cutting signal and flank wear curves provides useful indicators of unacceptable wear development in the tool.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.1
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• pp.78-87
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• 2001

This paper deals with the study on the cutting characteristics in ball-end milling process. First of all, the effects of the geometric cutting conditions such as the cutting speed, feedrates and the path interval on the surface integrity were evaluat-ed by the analytical and the experimental approaches. Secondly, the cutting mechanism model was developed to predict the cutting force accurately. It is possible for the proposed model to predict the shape error, estimate system stability and build the reliable adaptive control system. A large amount of experimental set are performed to show the validities of the proposed theories and to investigate the effect of cutting geometry such as rubbing effects, burr effects and etc.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.209-214
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• 2003

This study presents the analysis of ball end milling machinability and its application to the determination of the optimum feedrate in the CNC machining process of sculptured surface. The methods which estimate the cutting force system is approached experimentally. The estimation strategy, named technological processor, was applied to the machining process of sculptured surface for finding optimum variable feedrate. From the result of practical implementation for the test model, it is ascertain that the technological processor have brought the dispersion of force profiles. As compared with conventional imposing of cutting conditions, the machining time has reduced by more than 60%.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.9 s.186
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• pp.76-83
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• 2006

Machining accuracy is closely related with tool deflection induced by cutting forces. In this research, cutting forces and tool deflection in end milling are expressed as a closed form of tool rotational angle and cutting conditions. The discrete cutting fores caused by periodic tool entry and exit are represented as a continuous function using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping part are considered together far cutting forces and tool deflection estimation. Compared with numerical methods, the presented method has advantages in prediction time reduction and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the form accuracy is easily predicted from tool deflection curve.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.922-925
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• 2000

Generally, the machining accuracy in ball end milling directly depends on the rotational accuracy affected by the spindle speeds. The effects of spindle speeds for rotational accuracy in the high speed regions are more dominant than those in the low speed regions. This paper will investigate effects that the Increased speed affects on the rotational error according to the increase of a rotational speed and machining characteristics of the high speed ball-end milling in various rotational speeds and on various materials by using the high speed air-bearing spindle.

• Transactions of Materials Processing
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• v.16 no.1 s.91
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• pp.15-19
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• 2007

This paper presents an integrated machining error compensation method based on captured images of tool deflection shapes in flat end-milling processes. This approach allows us to avoid modeling machining characteristics (cutting forces, tool deflections and machining errors etc.) and accumulating calculation errors induced by several simulations. For this, a high-speed camera captured images of real deformed tool shapes which were cutting under given machining conditions. Using image processes and a machining error model, it is possible to estimate tool deflection in cutting conditions modeled and to compensate for machining errors using an iterative algorithm correcting tool paths. This corrected tool path can effectively reduce machining errors in the flat end-milling process. Experiments are carried out to validate the approaches proposed in this paper. The proposed error compensation method can be effectively implemented in a real machining situation, producing much smaller errors.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.34-39
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• 1999

If the on-line cutting conditions (e.g. speed, feedrate, radial and axal depth of cuts) can be identified in an end milling process, much information about cutting forces will be estimated from the cutting force model. Therefore, those estimated conditions can be applied to monitoring and control areas. In this paper, a real-time estimation algorithm for radial and axial depth of cuts is studied in end milling using the averaging cutting forces per tooth. The analytical estimation models of depth of cuts are derived from the geometric cutting force model. The validity of the estimation models is verified on a horizontal machining center through the experiments in various cutting conditions.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.485-491
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• 1999

A burr is formed in every corner of parts as a result of machining, which produces undesirable edge geometry and influence deeply to surface quality of workpiece. Therefore these burrs must be removed certainly. The cost of removing these burrs is directly proportional to their size. Burrs have been among the most troublesome obstruction to high productivity and automation of machining processes. The proper selection of cutting condition and tool geometry will be helpful to reduce the occurrence of burrs. In paper will observe burr formation along helix angle in end milling and certificate experimentally mechanics relation of helix angle and burr formation.

• Food Science and Biotechnology
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• v.16 no.6
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• pp.918-923
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• 2007

To investigate the relationship of wheat single kernel characteristics with end-use properties, 183 soft wheat cultivars and lines were evaluated for milling quality characteristics (kernel hardness, kernel and flour protein, flour ash), and end-use properties (i.e., as ingredients in sugar-snap cookies, sponge cake). Significant positive correlations occurred among wheat hardness parameters including near-infrared reflectance (NIR) score and single kernel characterization system (SKCS). The SKCS characteristics were also significantly correlated with conventional wheat quality parameters such as kernel size, wheat protein content, and straight-grade flour yield. The cookie diameter and cake volume were negatively correlated with NIR and SKCS hardness, and there was an inverse relationship between flour protein contents and kernel weights or sizes. Sugar-snap cookie diameter was positively correlated with sponge cake volume.