• 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 of Manufacturing Process Engineers
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• v.20 no.4
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• pp.87-93
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• 2021

The mold industry is competitive, and mold should be processed under optimal conditions for efficient processing. However, the cutting conditions of the ball-end mill, which are a major factor in mold processing, are mostly set empirically, and considerable research is required for increasing the tool life and processing accuracy. In this study, a tool dynamometer and an eddy current sensor were used along with NI-DAQ, a data acquisition device, to obtain characteristic values of the cutting force and tool deformation during the ball end-mill machining of inclined surfaces at a machining center. The cutting force and tool deformation were measured in an experiment. It was found that the tool received the greatest cutting force at the end of the machining process, and the deformation of the tool increased rapidly. Furthermore, the cutting force tended to increase with the angle and number of rotations. The deformation increased rapidly during the machining of a 45° inclined surface.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.10a
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• pp.274-278
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• 2000

Ball end milling process is widely used in the die and mould manufacturing because of suitableness for the machining of free form surface. But, as ball end mill is long and thin, it is easily deflected by cutting force. In this study, Cutting force, tool deflection and surface precision was measured according to the change of depth and cutting location. Cutting force was acquired with tool dynamometer and a couple of eddy-current sensor measured tool deflection in x-y direction each. After machining, surface precision was measured with roundness tester and coordination measuring machine for sculptured surface angle change and cutting depth.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.3
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• pp.437-446
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• 2013

There have been numerous studies on end milling processes. However, these have been restricted to the application of tools for special cutting purposes. A side milling cutter can handle long, deep, and open slots in a more efficient manner, and it provides the best stability and productivity for this type of milling. In this paper, a method to predict the cutting forces in side milling is described, and simulated cutting forces are compared with those obtained by cutting experiments. In particular, the side milling process easily generates relative motion between the tools and the workpiece because it produces intermittent cutting forces that cause vibrations over a wide frequency range. Therefore, the application of a dynamic cutting model instead of a static cutting model is appropriate to forecast the cutting forces more accurately.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.6 s.165
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• pp.979-987
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• 1999

In a high precision vertical machining center, the estimation of cutting forces is important for many reasons such as prediction of chatter vibration, surface roughness and so on, and cutting forces are difficult to predict because they are very complex and time variant. In order to predict the cutting forces of end-milling process for various cutting conditions, a mathematical model is important and this model is based on chip load, cutting geometry, and the relationship between cutting forces and chip loads. Specific cutting force coefficients of the model have been obtained as interpolation function types by averaging farces of cutting tests. In this paper, the coefficients are obtained by neural network and the results of the conventional method and those of the proposed method are compared. The results show that the neural network method gives more correct values than the function type and that in teaming stage as the omitted numbers of experimental data increases the average errors increase.

• Industrial Engineering and Management Systems
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• v.9 no.3
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• pp.242-250
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• 2010

For economical and environmental reasons, the aim of this research is hence to monitor the cutting conditions with the dry cutting, the wet cutting, and the mist cutting to obtain the proper cutting condition for the plain carbon steel with the ball end milling based on the consideration of the surface roughness of the machined parts, the life of the cutting tools, the use of the cutting fluids, the density of the particles of cutting fluids dispersed in the working area, and the cost of cutting. The experimentally obtained results of the relation between tool wear and surface roughness, the relation between tool wear and cutting force, and the relation between cutting force and surface roughness are correspondent with the same trend. The phenomena of surface roughness and tool wear can be explained by the in-process cutting forces. The models of the tool wear with the cutting conditions and the cutting times are proposed to estimate the tool cost for the different cooling strategies based on the experimental data using the multiple regression technique. The cutting cost is calculated from the costs of cutting tool and cutting fluid. The mist cutting gives the lowest cutting cost as compared to others. The experimentally obtained proper cutting condition is determined based on the experimental results referring to the criteria.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.5
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• pp.508-513
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• 2015

In this study, the effect of the helix angle and rake angle of a flat end-mill in the milling of titanium alloy was investigated. Tool shape parameters such as helix angle and rake angle affect the cutting force, cutting zone temperature, vibration, and chip flow mechanism, which in turn determine tool life, surface integrity, and dimensional accuracy of the milling process. To investigate the effect of the helix and rake angles, a certain range of parameters was selected, and three-dimensional tool models were generated for finite element analysis (FEA) for each case. The cutting force and pressure on the tool flank face and rake face were investigated by FEA. Further, several tool models were proposed for machining tests. The cutting force characteristics were investigated by the machining tests.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.1
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• pp.78-89
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• 1991

This Paper presents an application example of the Adaptive Robust Servocontrol (ARSC) scheme, which is an explicit (or indirect) pole-assignment adaptive algorithm with the property of "robustness". The ARSC scheme is applied to an end-milling process for cutting force regulation. It is shown that the federate of an end-milling process can be maximized by the adaptive regulation of the peak cutting force through the ARSC scheme. The results of simulation study and real cutting experiment are presented. It has been verified that asymptotic regulation can be achieved with robustness against the slowly time-varying perturbations to the process model parameters, which are caused by nonlinear cutting dynamics. dynamics.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.370-375
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• 2004

This paper presents an accurate cutting simulation and feedrate scheduling system for CNC machining. This system is composed of a cutting simulation part and a feedrate scheduling part. The cutting simulation part computes the geometric informations and calculates the cutting forces in CNC machining. The cutting force model using cutting-condition-independent coefficients was introduced for flat end milling and ball end milling. The feedrate scheduling part divides original blocks of NC code into smaller ones with optimized feedrates to adjust the peak value of cutting forces to reference forces. Some machining examples show that the developed system can control the cutting force at desired levels.

• Korean Journal of Computational Design and Engineering
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• v.3 no.3
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• pp.161-167
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• 1998

Cutting forces in ball-end milling of slanted surfaces are calculated. The cutting area is determined from the Z-map of the surface geometry and current cutter location. The obtained cutting area is projected onto the cutter plane normal to the Z-axis and compared with cutting edge element location. Cutting force is calculated by integration of elemental cutting forces of engaged cutting edge elements. Experiments with various slanted angles were performed to verify the proposed cutting force estimation model. It is shown that the proposed method predicts cutting force effectively for any geometry including sculptured surfaces with cusp marks and surfaces with pockets and holes.