• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.21-26
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• 2004

This research presents a modeling and a manufacturing method of insert type milling cutters such as face cutter, flat endmill and ball endmill. The methods introduced in this paper adopts the multi-tasking 5-axis machining that is increasing machining accuracy of holder and position accuracy of bolting points. So this can be used in the basic document of the total package program that involves modeling and manufacturing module in various insert cutters.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.11
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• pp.2664-2675
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• 1993

In this paper, the effects of chip breaker configuration on cutting forces for various cutting conditions are investigated and a method for predicting cutting forces effectively for chip breaker insert in milling is described. Based on the shear plane model and the relevant equations already existing for the relation among the parameters, the method makes use of the analytic geometric approach considering the configuration of cutting too by a 3-dimensional coordinate transformation matrix. The groove type chip breaker insert is modeled to be a double rake insert, represented by the first radial rake angle, the second radial rake angle and the length of land, and the program analyzing the cutting forces is developed. The program capability is verified by comparing the results with the experimental ones for a single cutter; and in case of primary cutting forces, the results of simulation and experiments agree very well showing 2%~16.7% difference within the feed rate range investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.237-240
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• 2004

Indexable end mills, which consist of inserts and cutter body, have been widely used in roughing of parts in the mold industry. The geometry and distribution of inserts on cutter body are determined by application. This paper proposes analytical cutting force model for indexable flat end-milling process. Developed cutting force model uses the cutting-condition-independent cutting force coefficients and considers runout, cutter deflection and size effect for the accurate cutting force prediction. Unlike solid type endmill, the tool geometry of indexable endmill is variable according to the axial position due to the geometry and distribution of inserts on the cutter body. Thus, adaptive algorithm that calculates tool geometry data at arbitrary axial position was developed. Then number of flute, angular position of flute, and uncutchip thickness are calculated. Finally, presented model was validated through some experiments with aluminum workpiece.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.2
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• pp.603-608
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• 2014

In many manufacturing such as the components of airplane and automobile, aluminum alloys(Al2024) which remarkable in low specific gravity and high strength have been utilized effectively. Face milling machining technology for surface roughness quality of workpiece has been applied in these fields. A face milling machining with chamfered throw away type insert tip can produce a perfect flat surface only in theory. But It is impossible because of many unwanted factors, namely, cutting temperature, plastic deformation, dynamic effect, etc. In this paper, experimental investigations are performed to improve surface roughness after high speed machining of Al2024 using qualified face milling cutter body for high speed machining.

• Journal of Korean Institute of Industrial Engineers
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• v.26 no.2
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• pp.165-170
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• 2000

In order to perform a successful material cutting process, the operators are to select the suitable machining tools and cutting conditions for the cutting environment. Up to now, this has been a complicated procedure done by the data in the tool manufacturers' paper catalog and the operator's experiencial knowledge, so called heuristics. This research is motivated by the fact that using computer techniques in processing vast amount of data and information, the operator can determine the tool and cutting condition easily. In the developed program, the selection of milling cutter, insert, and components are combined to provide optimal cutting speed, depth of cut, feed rate, rpm, and power. This program also provides the selection routine for end mill, drilling, turning, and grinding where the suitable tools are selected by workpiece, holder type, cut type, and insert shape.