• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.8
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• pp.1173-1182
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• 2001

Recent noticeable advances of CNC machine tools have considerably improved productivity and precision in manufacturing processes. However, in the respect of productivity some defects still remain because selection of machining conditions entirely depends on the experiences of programmers. Usually, machining conditions such as feed rate and spindle speed have been selected conservatively by considering the worst cases, and it has brought the loss of machining efficiency. Thus, the improvement of cutting force controller has been done to regulate cutting force constantly and to maximize feedrate simultaneously in case that machining conditions change variously. In this study, sliding mode control with boundary layer is applied to milling process for cutting force regulation and in a commercial CNC machining center data transfer between PC and PMC (programmable machine controller) of CNC machine is done using a standard interface method. And in the cutting force measurement, an indirect cutting force measuring system using current signal of AC servo is adopted in order not to use high-priced equipment like tool dynamometer. The purpose of this study is to maximize the productivity in milling process, thus its results can be applied to cases such as rough cutting process.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.4
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• pp.120-127
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• 2009

Spindle units of machine tool are very important part in the manufacturing area. Recently high speed machining has become the main issue of metal cutting. To develop high speed machine tools, a lot of studies have been carried out for high speed spindle. Due to increase of the rotational speed of the spindle, there has been renewal of interest in vibration of spindle. This paper concerns the improvement of spindle design using design of experiments. To improve the design of critical speed and weight of spindle, the experiments using central composite method have been carried out. The targets are critical speed and weight of spindle. For optimization of critical speed and weight and optimization of only critical speed by operation of all area search through response optimizer, the result of analysis has improved design of each factor. Finite element analyses are performed by using the commercial codes ARMD, CATIA V5 and ANSYS workbench. From the results, it has been shown that the proposed method is effective for modification of spindle design to improve critical speed and weight.

• Journal of Sensor Science and Technology
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• v.8 no.6
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• pp.469-475
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• 1999

The chips may be produced in the form of either broken chips or unbroken chips in turning process. The unbroken chips are dangerous to the operator and difficult to handle at high speed machining. The signal of Acoustic Emission is related to cutting conditions, tool materials, test conditions and tool geometry in turning. The relationship between AE signal and chip formation was experimentally investigated. The experimental results show that two types of chip formations are possible to classify from the statistical analysis of the amplitude of AE signal. The AE-sensor could be used to monitor the chip condition in turning.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.225-230
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• 2001

Small diameter drilling which take high precision in cutting work is needed more small hole and high speed working. Especially, small hole deep drilling is one of the most important machining types and its necessity and importance become more and more increasing in the whole field of industry. This paper shows the limit depths with small diameter drills using experimental analysis. The results are gained by tool dynamometer and Labview system and obtained during small diameter twist drilling system on SM45C steel for different machining conditions. The machine and tools are the CNC machining center and twist drill of diameter 1.5mm. And additionally, tool microscope show the relationship between shapes of chips and breakage shapes of small diameter drills.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.2
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• pp.281-285
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• 2008

Die hobbing is one of the dieblock manufacturing methods of cold forging die, which makes the upper side of dieblock indented using master punch, hobb to produce impression not using cutting work. SKD11, alloy tool steel was used as the material of dieblock and stainless sheet metal was used as product material in cold forging work. The life span of the die was 6,000 strokes. In this research, the material of dieblock was changed into SKH51, the high speed tool steel and the product material was S45C, the carbon steel in the cold forging work. The life span of the die was 21,000 strokes, which is 350% of the life span of the die using the former method.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.88-93
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• 2001

As the development of High Speed Machining, It is applied in many fields of manufacturing. Among them is to manufacture die and mold. But it still remains as a hard-to-work to apply it in machining pre-hardened materials such as hardened QRO90. It also difficult to machine new materials because there is no machining date of them. Therefore, in this study, we are trying to improve the machinability of new material, QRO90 by applying various cutting conditions, and selecting the best condition which not only reduce the machining time but improve the quality of die and mold made of QRO90 material.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.1
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• pp.33-40
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• 2010

In this research, the effects for surface Improvement of plasma ion implanted carbide endmill tools were observed by measuring cutting forces and tools wear affecting surface roughness in high speed cutting. From the 2nd ion mass analysis, the oxidation layer was found to be built up by sputtering. The residual gas contamination of oxygen was found to be contained impurities in nitrogen gas. The plasma implanted ion was found to be spreaded, especially the nitrogen was implanted up to 150nm depth as impressed voltage and ion implanting time. It is analyzed as bring surface improvement by spreading deeply forming oxidation on surface. The factors in Analysis of Variance(ANOVA) about mutuality cause reference of cutting force. The cutting force Fx is affected by the interaction of spindle rpm and federate, the cutting force Fy is influenced by spindle rpm and time injected ion, and cutting force Fz is affected by the interaction of impressed voltage and feedrate. Also, it was found that the cutting forces of implanted tools become lower and the surface roughness is improved by the effect of nitrogen according to the implantation.

• Journal of the Korean Society for Nondestructive Testing
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• v.33 no.1
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• pp.73-79
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• 2013

In this study, NIMAX material has been processed using the three-dimensional measuring instrument and white light interferometer. they were tested to roundness and surface roughness and results are as follows: As for a cutting characteristic, it indicated that F4 showed a lower result than 2F showed due to the high hardness of the material and showed a good result when spindle rotation speed and tool feed were low. As for the measurement of roundness through 3-Dimensional measuring machine, it indicated that 4F showed a good result like the condition of cutting component and that roundness showed a good result when spindle rotation speed of 1,700 rpm and tool feed speed of 85 mm/min were applied. As for the surface roughness of processing surface, Surface roughness showed better 4F than 2F and conditions of spindle rotation speed 1,700 rpm, tool feed rate 55 mm/min showed good results in the Ra $0.4025{\mu}m$.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.2
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• pp.351-358
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• 1993

Recently a high speed spindle system for machine tools has attracted considerable attention to reduce the machining time, to improve the machining accuracy, to perform the machining of light metals and hard materials and to unite the cutting and grinding processes. In this study, a high speed spindle system is developed by applying the oil-air lubrication method, angular contact ball bearings, injection nozzles with dual orifices and so on. And a lubrication experiment for evaluating the performance of the spindle system is carried out. Especially, in order to establish the lubrication conditions related to the development of a high speed spindle system, the effects of oil supply rate, rotational spindle speed and so on are studied and discussed on the bearing temperature rise, bearing temperature distribution and frictional torque. And the effect of spindle system structure on the bearing temperature distribution is investigated.

• Journal of the Korean Society for Precision Engineering
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• v.11 no.1
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• pp.123-128
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• 1994

A high speed spindle system for machine tools can be used to reduce the machining time, to improve the machining accuracy, to perform the machining of light metals and hard materials, and to unite the cutting and grinding processes. In this study, a high speed spindle system is developed by applying the oil-air lubrication method, angular contact ball bearings, injection nozzles with dual orifices, cooling jacket and so on. And an air cooling experiment for evaluating the performance of the spindle system is carried out. Especially, in ofder to establish the air cooling conditions related to the development of a high speed spindle system, the effects of cooling air pressure, oil supply rate, air supply rate and rotational spindle speed are studied and discussed on the bearing temperature rise and frictional torque. Also the effects of cooling air pressure, rotational spindle speed and spindle system structure is investigated on the bearing temperature distribution. The experiment on the test model reveals the usefulness of the air cooling method.