• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.2 s.233
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• pp.333-340
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• 2005

Feedrate is one of the factors that have the significant effects on the productivity, qualify and tool life in the cutting mechanism as well as cutting velocity, depth of cut and width of cut. In this study, in order to realize the high-efficient machining, a new feedrate optimization method is proposed based on the concept that the optimum feedrate can be derived from the allowable cutting power since the cutting power can be predicted from the cutting parameters as feedrate, depth of cut, width of cut, chip thickness, engagement angle, rake angle, specific cutting force and so on. Tool paths are extracted from the original NC program via the reverse post-processing process and converted into the infinitesimal tool paths via the interpolation process. And the novel NC program is reconstructed by optimizing the feedrate of infinitesimal tool paths. Especially, the fast feedrate optimization is realized by using the Boolean operation based on the Goldfeather CSG rendering algorithm, and the simulation results reveal the availability of the proposed optimization method dramatically reducing the cutting time and/or the optimization time. As a result, the proposed optimization method will go far toward improving the productivity and qualify.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.4
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• pp.214-222
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• 2003

Studies on the optimization of machining process can be divided into two different approaches: off-line feedrate scheduling and adaptive control. Each approach possesses its respective strong and weak points compared to each other. That is, each system can be complementary to the other. In this regard, a combined system, which is a feedrate control system fur cutting force optimization, was proposed in this paper to make the best of each approach. Experimental results show that the proposed system could overcome the weak points of the off-line feedrate scheduling system and the adaptive control system. In addition, from the figure, it can be confirmed that the off-line feedrate scheduling technique can improve the machining quality and can fulfill its function in the machine tool which has a adaptive controller.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.135-140
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• 2002

Studies on the optimization of machining process can be divided into two different approaches: off-line feedrate scheduling and adaptive control. Each approach possesses its respective strong and weak points compared to each other. That is, each system can be complementary to the other. In this regard, a combined system, which is a feedrate control system for cutting force optimization, was proposed in this paper to make the best of each approach. Experimental results show that the proposed system could overcome the weak points of two systems.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.547-552
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• 2003

In mold machining, there are many concave machining regions where chatter and tool deflection occur since MRR (material removal rate) increases as curvature increases even though cutting speed and depth of cut are constant. Boolean operation between stock and tool model is widely used to compute MRR in NC milling simulation. In finish cutting, the side step is reduced to about 0.3mm and tool path length is sometimes over 300m. so Boolean operation takes long computation time and includes much error if the resolution of stock and tool model is larger than the side step. In this paper, curvature of CL(cutter location) surface and side step of tool path is used to compute the feedrate for constant MRR machining. The data structure of CL surface is Z-map generated from NC tool path. The algorithm to get local curvature from discrete data was developed and applied to compute local curvature of CL surface. The side step of tool path was computed by point density map which includes cutter location point density at each grid element. The feedrate computed from curvature and side step is inserted to new tool path to regulate MRR. The resultants wire applied to feedrate optimization system which generates new tool path with feedrate from NC codes for finish cutting. The system was applied to speaker mold machining. The finishing time was reduced to 12.6%. tool wear was reduced from 2mm to 1.1mm and chatter marks and over cut on corner were removed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.57-58
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• 2012

• Journal of the Korean Society for Precision Engineering
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• v.21 no.4
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• pp.39-47
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• 2004

In mold machining, there are many concave machining regions where chatter and tool deflection occur since MRR(material removal rate) increases as curvature increases even though cutting speed and depth of cut are constant. Boolean operation between stock and tool model is widely used to compute MRR in NC milling simulation. In finish cutting, the side step is reduced to about 0.3mm and tool path length is sometimes over loom, so Boolean operation takes long computation time and includes much error if the resolution of stock and tool model is larger than the side step. In this paper, curvature of CL (cutter location) surface and side step of tool path is used to compute the feedrate for constant MRR machining. The data structure of CL surface is Z-map generated from NC tool path. The algorithm to get local curvature from discrete data was developed and applied to compute local curvature of CL surface. The side step of tool path was computed by point density map which includes cutter location point density at each grid element. The feedrate computed from curvature and side step is inserted to new tool path to regulate MRR. The resultants were applied to feedrate optimization system which generates new tool path with feedrate from NC codes for finish cutting. The system was applied to the machining of speaker and cellular phone mold. The finishing time was reduced to 12.6%, tool wear was reduced from 2mm to 1.1mm and chatter marks and over cut on corner were reduced, compared to the machining by constant feedrate. The machining time was shorter to 17% and surface quality and tool was also better than the conventional federate regulation using curvature of the tool path.

• 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%.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.690-694
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• 1996

In order to regulate the cutting force at a desired level during peripheral end milling processes, a feedrate override Adaptive Control Constant system was developed. This paper presents an explicit pole-assignment PI-control law through spindle motor current monitoring and its application to cutting force regulation for feedrate optimization. An experimental set-up is constructed for the commercial CNC machining center without any major changes of the structure. A data transfer system is constructed with standard interface between an IBM compatible PC and a CNC of the machining center. Experimental results show the validity of the system.

• Journal of Industrial Technology
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• v.16
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• pp.257-265
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• 1996

When machining of a free-form surface with a ball endmill it is very important to select proper cutting conditions considering the geometrical shape of a workpiece to make the production more effective and reduce the machining time. Even though the same cutting conditions and materials are used, the cutting system of different geometry part machining shows the different static/dynamic characteristics. In this study, through various cutting experiments, we can construct the data base of stable cutting conditions for the machining of a Zine Alloy. We can get some relational plots between the optimal feedrates and classified shape features and parameters. On the basis of these results, we can develop the feedrate optimization program OptiCode. The developed program make it possible to reduce the cutting time and increase the machining accuracies.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.5
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• pp.852-858
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• 2013

In numerical control (NC) machining, a machining error in equipment generally occurs for a variety of reasons. If there is a change in direction in the NC code, the characteristics of the automatic acceleration or deceleration function cause an overlap of each axis of the acceleration and deceleration zones, which in turn causes a shift in the actual processing path. Many studies have been conducted for error calibration of the edge as caused by automatic acceleration or deceleration in NC machining. This paper describes a geometric interpretation of the shape and processing characteristics of the operating NC device. The paper then describes a way to determine a feedrate that achieves the desired tolerance by using linear and parabolic profiles. Experiments were conducted by the validate equations using a three-axis NC machine. The results show that the machining errors were smaller than the machine resolution. The results also clearly demonstrate that the NC machine with the developed system can successfully predict machining errors induced with a change in direction.