• 한국산업융합학회 논문집
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• 제16권3호
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• pp.85-93
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• 2013

The MCT has been most extensively used in the machining. In particular, the ball endmill has been mainly adopted for finishing on the free- form surface. The advancement of CAD/CAM software has made it possible to develop various cutting pattern methods and to create diverse tool routes. Therefore, the current research made an attempt to find the optimal cutting pattern among the seven cutting patterns (i.e., Follow Periphery, Zig, Zig Zag, Concentric Zig, Concentric Zig Zag, Radial Zig, Radial Zig Zag) when aluminium 6000 series were machined by the ball endmill. The optimal pattern was found by comparing different shapes and surface roughness produced by the seven patterns. The current research found that each cutting pattern produced its own unique geometric features on the machined surface. It was found that the Radial Zig cutting pattern produced the lowest roughness on the flat surfaces. The Radial Zig Zag cutting pattern was found to produce the most accurate free-form surface. Finally, the most efficient cutting pattern in terms of machining time turned out to be the Follow Periphery.

• 한국정밀공학회지
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• 제18권7호
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• pp.112-119
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• 2001

In modern manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are being designed and produced to meet various sophisticated functional specifications. The cutting force is required not only for the design of machine and cutting tools, but also for the determination of the cutting conditions for the various machining operations. The ball-end mill is deflected by the cutting force and, the tool deflection is one of the main reasons of the machining errors on a free-form surface. Hence, The cutting force generated in the ball-end milling is the most important property of the machining. The purpose of this study is to find the characteristics of the cutting force in inclined plane and the resultant machining errors in the ball-end milling process. Although the depth of cut is constant in the inclined plane, the cutting force area varies due to the hemisphere of the ball-end mill.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2003년도 춘계학술대회 논문집
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• pp.1784-1788
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• 2003

For the improvement of geometrical accuracy in end milling, cutting method and cutting condition selection are investigated in this paper. As machining processes are composed of several steps such as roughing, semi-finishing. and finishing, cutting forces and tool deflection are calculated considering surface shape generated by the previous cutting. The effects of tool teeth numbers, tool geometry, and cutting conditions on the form error are analyzed. Using the from error prediction method from tool deflection, cutting condition for geometrical accuracy improvement is discussed. The characteristics and the difference of generated surface shape in up and down milling are dealt with and over-cut free condition in up milling is presented. The form error reduction method by alternating up and down milling is also suggested. The effectiveness of the presented method is examined from a set of cutting tests under various cutting conditions. This research contributes to cutting process optimization for the geometrical accuracy improvement in die and mold manufacture.

• 한국정밀공학회지
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• 제12권2호
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• pp.112-122
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• 1995

While many surfaces such as automobile outer panels, ship hulls and airfoils are characterized by their smooth, free-form shapes, a far larger class of functional surfaces are characterized by highly irregular, multi-featured shapes consisting of pockets, channels, ribs, etc. In constaract to the design of aesthetic, free-form surfaces, functional surface design can perhaps best be viewed as a process of assembling a collection of known component surfaces to form a single compound surface. In this paper, we presents a feature-based functional surface modeling method. A single feature involves a secondary surface, which we must join to a primary surface with a smooth transition between two boundary courves. Through recursive blending of a secondary surface with the primary surface, the mullti-featured surface is represented. After constructing a compound surface, we generate the Z-map for NC machining of the surface. Offsetting the Z-map using the inverse offsetting technique, we get CL tool paths with out gouging.

• International Journal of Precision Engineering and Manufacturing
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• 제3권4호
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• pp.43-53
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• 2002

Polishing a die that has free-form surfaces is a time-consuming and tedious job, and requires a considerable amount of high-precision skill. In order to reduce the polishing time and cope with the shortage of skilled workers, a user-friendly automatic polishing system was developed. The polishing system is composed of two subsystems, a three-axis machining center and a two-axis polishing robot. The system has five degrees of freedom and is able to keep the polishing tool in a position normal to the die surface during operation. A sliding mode control algorithm with velocity compensation was proposed to reduce tracking errors. Trajectory tracking experiments showed that the tracking error can be reduced prominently by the proposed sliding mode control compared to a PD (proportional derivative) control. To evaluate the polishing performance of the polishing system and to and the optimal polishing conditions, the polishing experiments were conducted.

• 한국정밀공학회지
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• 제19권12호
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• pp.171-178
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• 2002

With increasing the needs for micro and precision parts, micro machining technology using micro tools has been studied to fabricate a small part with high density such as electronics, optics, communications, and medicine industry more than before. Though these micro tools have developed rapidly, it is difficult to apply them to micro fabrication technologies, because of the inherent manufacturing. In this study, micro tools (WC) to produce micro structures and parts were manufactured by cylindrical grinding machine employing ELID (Electrolytic In-process Dressing) technique and the micro tools are fabricated as square shape with the dimension less than 100${\mu}{\textrm}{m}$. With the micro tools on the same machine, characteristics of micro grooving and drilling are evaluated. Also we compare normal micro machining with ultrasonic micro machining on the vibration table. It is confirmed that the developed micro tools are fully applicable to micro grooving, micro drilling and free form cutting.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 춘계학술대회 논문집
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• pp.1032-1035
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• 2000

Increasing demands on precision machining with computerized numerical control (CNC) machines have necessitated that the tool to move not only position error as small as possible, but also with smoothly varying feedrates in space. This paper presents a new high precision interpolation algorithm for 3-dimensional (3D) Non-Uniform Rational B-Spline (NURBS) curve in the reference-pulse CNC technique. Based on the minimum path error strategy, real-time NURBS interpolator was developed in software and this was implemented with a PC-NC milling machine. The several experimental results have shown that the proposed NURBS interpolator is useful for the high precision machining of complex shapes. It is expected that this algorithm can be applied to the CNC machines for the machining of 3D free-form surfaces.

• 한국정밀공학회지
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• 제18권6호
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• pp.43-49
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• 2001

A reduced machining time and increased accuracy for the sculptured surface are very important when producing complicated parts. The step-size and tool-path interval are essential components in high speed and high resolution machining. If they are small, the machining time will increase, whereas if they are large, rough surfaces will be caused. In particular, the machining time, which is key in high speed machining, is affected by the tool-path interval more than the step-size. The conventional method for calculating the tool=path interval is to select a small parametric increment of a small increment based on the curvature of the surface. However, this approach also has limitations. The first is that the tool-path interval can not be calculated precisely. The second is that a separate tool-path interval needs to be calculated in each of the three cases. The third is that the conversion from Cartesian domain to parametric domain or vice versa must be necessary. Accordingly, the current study proposes a new tool-path interval algorithm that do not involve a curvature and that is not necessary for any conversion and a variable step-size algorithm for NURBS.

• 한국정밀공학회지
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• 제10권3호
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• pp.161-167
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• 1993

This paper deals with a new method for the machining of a die cavity defined by sculptured surfaces. In machining die cavities or pockets, process planners have been faced with some troulbes. One of the troubles ius to rebove a great deal of material within a given boundary while avoiding cutter interference. Cutter interference is a ciritical problem in NC machining of a die cavity. Even though this cavity machining has been implemented in many CAM systems, most of them can handle limited shapes of cavities or pockets. In this paper, a procedure has been developed to machine die cavity or pocket of a sculptured surface. The offset surfaces of the part surfaces and boundary surfaces are determined to calculate the intersection curves. These intersection curves form a FACE on the part surface, and the interference free tool pathe is generated by eliminating the points outside the FACE when computing the cutter contact (CC) data. Additionally, the cutter location (CL) data obtained from the CC data convert to an NC data. The NC data generated through this algorithm are verified on the CINCINNATI milling machine. A propotype die cavity machining system has been implemented in FORTRAN language and FIGARO graphics library on IRIS workstation.

• 한국생산제조학회지
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• 제8권2호
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• pp.116-116
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• 1999

In this study we propose a novel approach with which design engineers can define and design free-from surface more easily. Free-from surface is defined as a parameterics shape which consists of a set of contr ol points. Parametric shape which not only has the advantage of allowing users to perform design changes efficiently, but also provides designers with a natural design environment in which they can do their work more naturally and creatively. The objective of this study is to develop a PC level freeform surface modelling system which explicitly represents information of part geometry. In this study, freeform surface modeling system consist of three modules : freeform surface modeler, input/output modules and interface with Database. In recent year there are increasing demands for the 5-axis machining of a complicated shape. This study is the development of a CAM software system (or NC module) for the 5-axis machining of a general shape with a flat-end mill, a round-end mill, a ball-end mill.