• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.295-296
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• 2006

High hardness of P/M parts can be obtained in the cooling section of the sintering furnace by using sinter hardenable materials, thus the post-sintering heat treatment can be eliminated. However, the sinter hardened materials would have difficulties in secondary machining if it is required, which will limit the applications of sinter hardenable materials in the machined parts. Recent development in warm compaction technology can enable us not only to achieve the high green density up to $7.4\;g/cm^3$, but also the high green strength which is needed for green machining. Therefore by using warm compaction technology, the green machining can be applied to sinter hardenable materials for the high density, strength and hardness P/M parts. In the present study, a pre-alloyed steel powder, ATOMET4601, was used by mixing with 2.0% copper, 1.0% nickel, 0.9% graphite and a proprietary lubricant using a binder treatment process - FLOMET. The specimens were compacted and green machined with different machining parameters. The machined surface finish and part integrity were evaluated in selecting the optimal conditions for green machining. The possibility of applying the green machining to the high-density structural parts was explored.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.3
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• pp.75-81
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• 2003

Pocket machining is metal removal operation commonly used for creating depressions in machined parts. Numerically controlled milling is the primary means for machining complex die surface. These complex surfaces are generated by a milling cutter which removes material as it traces out pre-specified tool paths. To machine, a component on a CNC machine, part programs which define the cutting tool path are needed. This tool path is usually planned from CAD, and converted to a CAM machine input format. In this paper I proposed a new method for generating NC tool paths. This method generates automatically NC tool paths with dynamic elimination of machining errors in 2$\frac{1}{2}$ arbitrary shaped pockets. This paper generates a spiral-like tool path by dynamic computing optimal pocket of the pocket boundary contour based on the type and size of the milling cutter, the geometry of the pocket contour and surface finish tolerance requirements. This part programming system is PC based and simultaneously generates a G-code file.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1997.10a
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• pp.43-47
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• 1997

Advances in EDM power supplies have made the process competitive in some areas dominated by conventional and numerically controlled machines. This paper will produce more comprehensive data than are presently available and will use this data in applying concepts of optimization based on manufacturer's guide lines utilizing neural networks. A method will be developed for determining the machining parameters of the EDM process considering the conflicting desirability of good surface finish, low tool wear and high rates of metal removal. By the proposed method, one can select machining parameters that can maintain permissible tool wear and obtain maximum machining rates on the system represented by the data.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.569-574
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• 2002

As consumer's desire becomes various, agility of mold manufacturing is most important factor for competence of manufacturer. In common works to use commercial CAM system to generate tool path, some decision making process is required to produce optimal result of CAM systems, The paper proposes a methodology for computer-assisted tool selection procedures for various cutting type, such as rough, semi-rough and finish cuts. The system provides assist-tool-items for machining of design model part of injection meld die by analyzing sliced CAD model of die cavity and core. Also, the generating NC-code of the tool size is used to calculate machining time. The system is developed with commercial CAM using API. This module will be used for optimization of tool selection and planning process.

• Korean Journal of Computational Design and Engineering
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• v.4 no.3
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• pp.247-258
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• 1999

With the contemporary CAD/CAM system, where the tool path is generated and verified purely based on the geometric operation, geometric accuracy of the machined surface cannot be guaranteed dut to the cutting mechanics, meaning that the cutting mechanics should be incorporated in some fashion. In this paper, we incorporate the instantaneous cutting force and the tool deflection phenomena in predicting the machined surface for the finish-cut and milling operation. For the given NC dat including cutting conditions, the developed algorithm computes cutting force and deflection amount along the tool trajectory, and outputs the 3D graphic model of the machined surface together with error analysis. The validity and accuracy of the presented method has been tested by the actual cutting experiments. Experimental results and accuracy enhancement method together with implementing architecture of the VMCS (Virtual Machining CAM System) are discussed in the paper.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.6
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• pp.1483-1495
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• 1994

A quantitative analysis of a surface roughness for a precision machining of a sculptured surface in milling process is treated under superposition theory in this paper. The geometrical surface rouhgness is calculated as a function of feed per tooth, path interval, radii of tool and cutting edge, and radii of curvatures of workiece. Through machining experiments in a 3-axis machining center, we confirmed the adequacy of the adequacy of the analysis. While cutter mark is neglegible in ball endmilling, it is significant in flat endmilling. When feed per tooth is very small, flat endmilling gives superior finish to ball endmilling. In flat endmilling, cutting condition and cutter path should be strategically chosen to balance the cutter mark height and cusp height.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.1
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• pp.43-50
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• 2009

Semi dry cutting known as MQL (Minimum Quantity Lubrication) machining is widely spreaded into the machining shops nowadays. The objective of this research is to suggest how to derive optimum cutting conditions for the milling process in MQL machining. To reach these goals, a bunch of finish milling experiments was carried out while varying cutting speed, feed rate, oil quantity, depth of cut and so on with MQL. Then, response surface analysis was introduced for the variance analysis and the regression model with the experimental data. Finally, desirability function based on regression model was used to obtain optimal cutting parameters and verification experiment was done.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.3
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• pp.71-76
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• 2020

Various machining methods are being studied to improve the processing quality of the spherical R shape in press die. In this paper, we confirmed that changes in machining quality were associated with changes in cutting direction, path, and cutting angle, which are commonly used in the machining of molds. We obtained a surface roughness graph with each condition change in one specimen using an instrument that measured geometry and surface roughness simultaneously. The results of the study showed that the best surface roughness in the finish cut of the spherical surface was obtained using upward pick feed machining.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.9
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• pp.34-40
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• 2002

Machining accuracy is affected by quasi-static errors of machining center. Since machine errors have a direct influence upon both the surface finish and geometric shape of the finished workpiece, it is very important to measure the machine errors and to compensate these errors. The laser measurement method for identifying geometric errors of machine tool has the disadvantages such as high cost, long calibration time and usage of volumetric error synthesis model. Accordingly, this paper deals with analysis of the geometric errors of a machine tool using ball bar test without using complicated error synthesis model. Statistical analysis method was adopted in this paper for deriving geometric errors using hemispherical helix ball bar test. As a result of experiment, geometric errors of the vertical machining center are compensated by 88%.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.6
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• pp.739-745
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• 2010

The roller gear cam can control the rotational follower periodically by attaching several roller on the circumstance of follower shaft and it is widely used in non-backlash and precise actuating mechanism such as index table or ATC of machine tools. For machining the roller gear cam, 5 axis CNC machine tool is used and the geometric principle of CAM mechanism must be adopted to generate the NC-code and to develop the special CAD/CAM software because there is not commercial CAM system to machine the roller gear cam. The maker of the specially developed software in domestic user is generally from Japan or Taiwan. However these softwares do not reflect the post processing technique for finish machining in the module. Also, there is some limitation for further new application of itself and it needs higher costs for further application. In this study, the CAD/CAM software to overcome these problem was developed. And its reliability was verified by applying it in 5-axis CNC machining. Finally, the experimental result conducted in the 5-axis machining show good consistency in the movement of follower along the flute and in its Size.