• 한국정밀공학회지
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• 제17권6호
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• pp.162-168
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• 2000

The automatic die polishing machine by liquid honing has been developed and experimented on the surface of machined die. The goal of development in the automatic die polishing machine by liquid honing is to increase the accuracy and the productivity in die polishing. To reach this goal, the polishing machine consists of the automatic measuring device for contour of die, the nozzle and pumping system to spray the powder mixed with liquid, and the 3-axis guides. Before polishing, the measuring device with a semiconductor laser scans the surface of mould to get the data of contour. The data store a PC and use to control the nozzle head to move above a couple of centimeters on the machined surface of die. The experimental parameters are the spraying time, the pressure, the size of abrasive grain and the mixing ratio between abrasive grain and liquid. The surface roughness is measured on the polished die which are SKDl 1 and Al7075 machined by NC. The surface roughness indicates the values of Rmax 0.5${\mu}{\textrm}{m}$ for Al7075 and Rmax 1.4${\mu}{\textrm}{m}$ for SKDl 1. It reduces the polishing time significantly and reduces the monotonous work for labors. As the results, the liquid honing system is useful method to apply for the die polishing and the automatic die polishing machine using liquid honing shows that it's very effective processing ability.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2001년도 추계학술대회 논문집
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• pp.106-110
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• 2001

The ball-end milling process is widely used in the die/mold industries, and it is very suitable for the machining of free-form surfaces. However, this process is inherently inefficient process to compared with the end-milling or face milling process, since it relays upon the machining at the cutter/surface contact point. The machined part is the result of continuous point-to-point machining on the free-form surface. And cusps (or scallops) remain at the machined part along the cutter paths and they give the geometrical roughness of the workpiece. Thus, for the good geometrical roughness of the workpiece, it is required very tightly spaced cutter paths in this ball-endmilling process. However, with the tight cutter paths, the geometrical roughness of the workpiece is not regular on the workpiece since the cusp height is variable in the previously developed ISO-parametric or Cartesian machining methods. This paper suggests a method of tool path generation which makes the geometrical roughness of workpiece be constant through the machined surface. In this method, Ferguson Surface design Model is used and cusp height is derived from the instantaneous curvatures. And, to have constant cusp height, an increment of parameter u or v is estimated along the reference cutter path. In ball-end milling experiments, the cusp pattern was examined, and it was proved that the geometrical roughness could be regular by suggested tool path generation method.

• 한국기계가공학회지
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• 제9권6호
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• pp.1-6
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• 2010

Patterned optical components are widely used for optical products such as LCD and lighting. Since CCFL was used as a light source in the products, prism films having linear continuous optical patterns were widely used. However, LED which is a dot light source is popular recently, therefore, the optical products need new optical components having non-continuous optical patterns. Indentation machining method is a powerful method for machining of non-continuous pattern. When a copper mold and a brass mold were machined by this method, severe plastic deformation called pile-up was observed around the patterns. Since pile-up has negative relationship to ductility, this deformation can be eliminated by annealing treatment which makes the materials ductile. No plastic deformation occurred when machined after annealing at $600{^{\circ}C}$ and $575{^{\circ}C}$ for copper and brass, respectively. Finally, non-continuous optical patterns with high quality were machined on a copper mold and a brass mold successively.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2003년도 춘계학술대회
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• pp.1111-1117
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• 2003

NURBS (Non Uniform Rational B-Spline) is widely used in CAD system and NC data for high speed machining. Conventional CAM system changes NURBS surface to tessellated meshes or Z-map model, and produces linear tool path. The linear tool path is not good for precise machining and high speed machining. In this paper, an algorithm to change linear tool path to NURBS one was studied, and the machining result of NURBS tool path was compared with that of linear tool path. The N-post, post-processing and virtual machining software was developed. The N-Post post-processes linear tool path to NURBS tool path and quickly shades machined product on OpenGL view and compares a machined product with original CAD surface. A virtual machined model of original tool path and post-processed tool path was compared to original CAD model. The machining error of post-processed NURBS tool path was reduced to 43%. The original tool path and NURBS tool path was used to machine general model using same machine tool and machining condition. The machining time of post-processed NURBS tool path was reduced up to 38%.

• Design & Manufacturing
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• 제14권1호
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• pp.63-68
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• 2020

Ultra-high brightness and thin displays need to optical micro-patterns which can uniformly diffuse the lights and low loss. The micro random patterns have characteristics to rise the optical efficiency such as light extraction, uniform diffusion. For this reason, various fabrication processes are studied for random patterns. In this study, the micro random patterns were machined by diamond turning which used a controlled cutting tool path with random cutting depth. The machined patterns had random shape and directionality along the circumferential direction. The average width and length of machined random pattern according to rotation radius were 40.13㎛~55.51㎛ and 37.25㎛~59.49㎛, and these results were compared with the designed result. Also, the machining error according to rotation radius in diamond turning using randomly controlled cutting depth was discussed.

• 한국정밀공학회지
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• 제30권12호
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• pp.1265-1271
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• 2013

In this work, modeling and analysis of thermal effects laser drilling under water for ceramics were presented. Laser is a unique tool for machining ceramics due to the characteristic of non-contact material removal. However, ablation by a laser often induces a thermal effect on the material and an increased heat-affected-zone or deposition of debris can be observed on the machined parts. The underwater surrounding improved a heat transfer rate to cooling down the machined part and could prevent any deposition of debris near the machined surfaces and edges. The heat modeling was applied to obtain the temperature distributions as well as temperature gradients between the material and surroundings. The cooling effect of the underwater laser drilling was improved and a more stable temperature distribution was calculated. The actual laser drilling results of ceramic laser drilling were presented to verify the effects of underwater laser drilling.

• 한국정밀공학회지
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• 제6권3호
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• pp.68-77
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• 1989

The surface rolling for cylindrical surface of a grey cast iron was carried out using a lathe with a simple newly-designed tool system. A surface rolling tool used was steel ball whose diameter was 3/8 inch (9.525mm) The effects of rolling feeds and number of rolling on surface rolling were investigated. The contact pressure between ball and workpiece which was considered as Hertz's contact problem was examined and the track of motion of a ball on the cylindrical surface of a work- piece was measured according to the rolling feed. The results obtained were as follows; 1. The roughness of the machined surface which was originally 5.3 .approx. 28 umRz decreased to 1.2 .approx. 5 umRz according to rolling feeds and numbers of rolling. 2. The hardness increased from Hv 260 to Hv 290 .approx. 310 through 2 .approx. 4 rollings according to the roughness of machined surfaces. 3. The reduction of diameter was found to be proportional to the variations of roughness of previous machined surfaces. About 60% to 90% of reduction in diameter was made during the first rolling process. 4. An equation relating the reduction of diameter and the variation of surface roughness after surface rolling was presented using a geometric surface model. 5. An equation for the calculation of dynamic contact area between pressure ball and workpiece according to the rolling feed was presented.

• 한국정밀공학회지
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• 제27권10호
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• pp.45-51
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• 2010

Electrical discharge drilling (ED-drilling) is a widespread machining method used to bore small holes with a high aspect ratio. This paper presents additional methods by which ED-drilling can improve machining speed, tool wear, and machined surface quality. Firstly, for high machining speed, and low tool wear, a new-type electrode that was ground on one side or both sides of the cylindrical electrodes was suggested to expel debris. The debris which is generated during the machining process can cause sludge deposition and secondary discharge problems: major reasons to decrease machining speed. This new-type electrode also reduced tool wear that was due to the decrease of unstable discharge in a machining gap by helping to expel waste water and debris from the gap. Secondly, to improve the machined surface roughness, an electrolyzation process was included after drilling. This process made the machined surface smooth by means of an electrochemical reaction between an electrode and a workpiece. In this study, the machining speed, electrode wear, and surface roughness were improved by the newtype electrode and the electrolytic process.

• 한국정밀공학회지
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• 제19권9호
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• pp.66-73
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• 2002

Since cross-feed directional cutting force which is normal to machined surface directly influences the machined surface of the workpiece and total force loaded in cutter, it is necessary to estimate this force to control the roughness of the machined surface and total force in cutter. However, there have been difficulties in using the current existing in a stationary motor for cutting state prediction because of some unpredictable behavior of the current. Empirical approach was conducted to resolve the problem. As a result, we showed that the current and its unpredictable behavior are related to the infinitesimal rotation of the motor. Subsequently, the relationship between the current and the cutting force was identified with the error less than 50%. And, the estimation results of the two machine tools with different characteristics were compared to each other to confirm the validity of the presented estimation method and the characteristics of current of the stationary feed motor.

• 한국정밀공학회지
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• 제16권10호
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• pp.11-16
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• 1999

In this study, Ultra-precision finishing system using micro abrasive film experimented using experimental variable film feed speed and grinding speed and structural steel(SM45C) with respect to 12~3{\mu}m$ micro abrasive film. the result are follows; (1) Experimental condition must setup dissimilar about each micro abrasive film. (2) To measurement deviation the smallest machined condition are 20mm/min in 12{\mu}m$, 5mm/min and 15mm/min in 9{\mu}m$ and 5{\mu}m$, 5mm/min in 3{\mu}m$ in film feed speed. (3) To measurement deviation the smallest machined condition are 180m/min in 12{\mu}m$, 84m/min in 9{\mu}m$, 56 and 84m/min in 5{\mu}m$, 104m/min in 3{\mu}m$ in grinding speed.