• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2004년도 춘계학술대회 논문집
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• pp.404-409
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• 2004

To maximize the productivity in machining molds and dies, machine tools should operate at high speeds. During the high speed operation of moving frames or spindles, vibration problems are apt to occur if the machine tool structures are made of conventional steel materials with inferior damping characteristics. However, self-excited vibration or chatter is bound to occur during high speed machining when cutting speed exceeds the stability limit of machine tool. Chatter is undesirable because of its adverse effect on surface finish, machining accuracy, and tool life. Furthermore, chatter is a major cause of reducing production rate because, if no remedy can be found, metal removal rates have to be lowered until vibration-free performances is obtained. Also, the resonant vibration of machine tools frequently occurs when operating frequency approaches one of their natural frequencies because machine tools have several natural frequencies due to their many continuous structural elements. However, these vibration problems are closely related to damping characteristics of machine tool structures. The polymer concrete has high potential for machine tool bed due to its good damping characteristics with moderate stiffness. This paper presents the use of polymer concrete and sandwich structures to overcome vibration problems. Also, co-cure bonding method for functional part mounting was exhibited experimentally, by which manufacturing time and cost for polymer concrete bed will be remarkably reduced.

• 한국레이저가공학회지
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• 제18권4호
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• pp.17-22
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• 2015

In this paper, ablation rate of $Al_2O_3$ ceramics by femtosecond laser fluence is derived with experimental method. The automatic three axis linear stage makes laser optics to move with high spatial resolution. With 10 times objective lens, minimal pattern width of $Al_2O_3$ is measured in the focal plane. Ablated surface area is shown as linear tendency increasing number of machining times with various laser power conditions. Machining times is most sensitive condition to control $Al_2O_3$ pattern width. Also, the linear increment of pattern width with laser power change is investigated. In high machining speed, the ablation volume rate is more linear with fluence because pulse overlap is minimized in this condition. Thermal effect to surrounding medium can be minimized and clean laser process without melting zone is possible in high machining speed. Ablation volume rate decelerates as increasing machining times and multiple machining times should be considered to achieve proper ablation width and depth.

• 한국기계가공학회지
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• 제12권6호
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• pp.30-36
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• 2013

An FFD(flexible fine die) is an embossed mold that consists of a thin plate ranging from 0.6 to 3 mm in thickness. FFDs are primarily used for cutting LCD films and F-PCB sheets. In the high-speed micro-milling process of flexible fine dies, the lubrication and cooling of the cutting edges is very important from the aspect of eco machining and cutting performance. In this paper, a comparative study of tool wear and surface roughness between cutting fluid and hybrid lubrication for eco-machining of FFD was conducted for processes of high-speed machining of highly hardened material (STC5, HRC52). Especially, the incorporated fluid method for eco machining, in which the cutting performances can be simultaneously measured, was introduced. The machining results show that hybrid lubrication, instead of conventional cutting fluid, leads to excellent tool wear and surface roughness and represents the proper conditions for eco micro-machining of flexible fine dies.

• 한국산학기술학회논문지
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• 제14권9호
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• pp.4149-4155
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• 2013

더 빠른 절삭속도와 이송속도를 위한 고속가공은 표면품위와 재료제거율의 증가를 초래한다. 이 논문은 고속가공을 위한 정면밀링커터를 사용한 가공에서 획득된 진동특성에 관한 절삭조건의 영향을 연구하였다. 이 논문에서, 직교배열 테이블에 기초한 다구찌 실험계획법은 고속 정면밀링커터를 사용한 진동특성을 연구하기 위해 적용되었다. 실험조건은 직교배열 $L_{27}(3^{13})$ 을 사용하였다. 실험의 계획과 분석은 S/N비(신호 대 잡음비)와 분산분석을 이용하여 진동에 관한 절삭조건의 영향을 연구하기 위해 수행되었다. 절삭 파라미터 즉 이송속도, 챔퍼길이, 절삭속도 그리고 절삭깊이는 진동 특성치를 고려하여 최적화 되었다.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2003년도 춘계학술대회 논문집
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• pp.589-592
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• 2003

In the machining process of micros shape by using high-precision machining system and micro end-mill, it is important for machining characters of tools to be grasped in order to stably use tools of micro end-mill. In this study. we carried out an analytical experiment of basic machining features by using end-mill tools for the purpose of damage prevention and manufacture of high quality when the tools of micro end-mill are used. This experiment used a micro machining system with high precision and a variety of end-mill tools commercialized from tens to hundreds microns in diameter. To establish an optimal machining condition without tool damage, cutting force was analyzed according to the changes of tool diameter and cutting conditions such as cutting speed. feed rate, depth of cut. And an examination was performed for the shape and surface illumination of machining surface according to the changes of machining conditions. Based on these micro machining conditions, micro square pillar, cylinder shaft. thin wall with high aspect ratio, and micro 3-D structures such as micro gear and fan were manufactured.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2001년도 춘계학술대회 논문집
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• pp.28-31
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• 2001

Recently, in order to satisfy the consumer's demand the life cycle and the lead-time of a product is to be shortened. It is thus important to reduce the time and cost in manufacturing trial products. Several techniques have been developed and successfully commercialized in the market RPM(Rapid Prototyping and Manufacturing). However, most commercial systems currently use resins or waxes as the raw materials. So, the limited mechanical strength for functional testing is regarded as an obstacle towards broader application of rapid prototyping techniques. To overcome this problems, high-speed machining technology is being investigated worldwide for rapid manufacturing and even for direct rapid tooling application. In this paper, some fundamental experiments and analyses are carried out to obtain the filling time, materials, method, and process parameters for HisRP process. HisRP is a combination process using high-speed machining technology with automatic filling. In filling process, Bi58-Sn alloy is chosen because of the properties of los-melting point, low coefficient of thermal expansion and enviromental friendship. Also the use of filling wire is of advantage in term of simple and flexible mechanism. Then the rapid manufacturing product, for example a skull, is machined for aluminum material by HisRP process with an automatic set-up device of 4-faces machining.

• 한국정밀공학회지
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• 제19권3호
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• pp.88-94
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• 2002

Recently, the life cycle and the lead-time of a product are to be shortened in order to satisfy consumer's demand. It is thus important to reduce the time and cost in manufacturing trial products. Several technique have been developed and successfully commercialized in the market of RPM(Rapid Prototyping and Manufacturing). However, most commercial systems currently use resins or waxes as the raw materials. So, the limited mechanical strength for functional testing is regarded as an obstacle towards broader application of rapid prototyping techniques. To overcome these problems, high-speed machining technology is being investigated worldwide for rapid manufacturing and even for direct rapid tooling application. In this paper, some fundamental experiments and analyses are carried out to obtain the filling time, materials, method, and process parameters for HisRP(High-Speed RP) process. HisRP is a new RP process that is combined high-speed machining with automatic filling. In filling process, Bi58-Sn alloy is chosen as filling material because of the properties of low-melting point, low coefficient of thermal expansion and no harm to environment. Also the use of filling wire it if advantage since it needs simple and flexible mechanism. Then the rapid product, for example a skull, is manufactured for aluminum material by HisRP process with an automatic set-up device thor 4-faces machining.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.993-996
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• 2005

High speed machining(HSM) technique is widely used in the appliance, automobile part and mold industries, which has many advantages such as good quality, low cost and rapid machining time. but it also has problems like tool break, smooth tool path, and so on. In particular, small size end mill is easy to break, so it must be changed before interrupting operation. Generally, the tool life of small size end mill is effected by the milling conditions whose evaluated parameters are spindle, feedrate, and width of cut. The experiments are carried out by full factorial design of experiments using and orthogonal array. This paper shows optimal combination and mathematical model for tool life, and the analysis of variance(ANOVA) is employed to analyze the main effects and the interactions of these milling parameters and the second-order polynomial regression model with three independent variables is estimated to predict tool life by multiple regression analysis.

• 한국정밀공학회지
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• 제23권8호
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• pp.195-202
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• 2006

High-speed machining (HSM) with excellent quality and dimensional accuracy has been widely used to create 3D structures of metal and plastics. However, the high-speed machining process is not suitable for the rapid realization of 3D thin-walled product because it consumes considerably long time in fixturing process of a work piece. In this paper, an effective rapid manufacturing process is proposed to fabricate 3D thin-walled products directly using HSM, phase change filling and ultrasonic welding. The filling process is useful to hold the thin-walled product during the machining step. The ultrasonic welding process is introduced to make one piece product from two piece parts that are machined by HSM and filling process. The proposed rapid manufacturing (RM) process has been shown that the RM process enables to fabricate the 3D thin-walled products using ABS plastics and aluminum metals from 3D CAD data to functional parts.

• 한국기계가공학회지
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• 제18권6호
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• pp.26-32
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• 2019

Ball end mills used for high-speed and high-precision machining require longer machining time than flat end mills or face cutters, since the tool diameter is limited and the rigidity is reduced by the characteristics of the tool's cutting edge: at the top end of the tool, the cutting speed approaches zero and hardly removes any material. Because there is little material removal at the top end of the ball end mill, the outer cutting edge performs the majority of the work; this irregular cutting force deforms the tool and shortens its life. In this study, we attached an eddy-current sensor to a tool to measure the deformation from the cutting force and we used a tool dynamometer to measure the cutting force. We found that the change in cutting force is dependent on the change in feed rate during square-shaped processing and, as the feed rate is accelerated, the cutting force also increases. Higher cutting forces increase tool deformation.