• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.1
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• pp.31-36
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• 2009

Micro-machining technology has been adopted for shape accuracy of micrometer and sub-micrometer scale, surface roughness of tens nanometer in industries. In micro-machining process the quality of machined surface is derived from machining condition and tooling. This paper investigates AE(acoustic emission) and cutting force signals according to machined surface quality related to machining condition. Machined surface quality was analyzed by the AE and cutting force parameter which reflect surface morphology. The characteristics of signal were extracted for process optimization by monitoring both the tool condition and the machined surface texture in micro end milling process.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.1
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• pp.78-83
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• 1996

This paper presents the characteristics of surface roughness and cutting force in ultraprecision cutting of aluminium alloy using natural diamond tools whose edge radii are smaller than those of tools made of other materials. The feed rate and depth of engagement were set to be a micrometer order. After measuring the surface roughness of machined surface and cutting force for each cutting condition, the relations between the surface quality and its condition were investigated qualitatively. If the feed rate was under a certain limit, the machined surface quality was deteriorated unexpectedly. This is supposed to have happened due to vibration leading its condition to abnormal one. In a certain situation the machined surface roughness by a natural diamond tool was inferior to that made by a carbide tool whose cutting edge radius is larger. This is supposed to be caused by not normal machining but burnishing effect.

• Tribology and Lubricants
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• v.11 no.5
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• pp.31-39
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• 1995

The surface integrity of a machined surface is an important factor that dictates several performance characteristics of a metal part. In this paper, the surface integrity aspects are presented specifically with respect to the tribological properties of steel. Test specimens were prepared under varying conditions to induce different levels of surface deformation and hardness. Sliding and rolling experiments were performed to assess the friction and wear characteristics of these specimens using a pinon-disk type tribotester and a plate-on-ball type set-up. It is reaffirmed that heat treated steels possess superior sliding and rolling fatigue resistance than raw steel. However, for the case of raw steels machined under varying conditions, the harder specimen resulted in higher wear. This result is attributed to the presence of surface cracks that were induced during machining. The results of such findings will aid in the optimization of surface preparation process for tribological applications of steel.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.31 no.2
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• pp.11-18
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• 2008

Surface roughness is an important factor to evaluate machined parts in precision machining. This is the major measure of surface quality. This research sets up experiments to select the factors which affect surface roughness in the machining of inclined planes of aluminum. The levels of the selected experimental factors are chosen to evaluate the relationship between the surface roughness of the machined parts and machining parameters. This is to find out the optimal machining condition in the inclined planes. The objective of this research is to improve the surface roughness of the machined products by using the ANOVA analysis. The factors for the experiments are cutting speed, feed rate, cutting depth, and cutting width. The experimental levels of the factors are two for the cutting depth and width. For the cutting speed and feed rate, their levels are three because they are more sensitive for the surface roughness than the other two. The inclined planes are machined by 5-axis machining equipment.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.12
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• pp.1088-1095
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• 2008

5-axis NC machining has a good advantage of the accessibility of tool motion by adding two rotary axes. It offers numerous advantages such as expanding machining fields in parts of turbo machineries like impeller, propeller, turbine blade and rotor, reasonable tool employment and great reduction of the set-up process. However, as adding two rotary axes, it is difficult to choose suitable machining conditions in terms of tool path, tool posture, feedrate control at a tool tip and post-processing. Therefore in this paper, it is proposed to decide suitable machining condition through an experimental method such as adopting various tool paths, tool postures, and feedrate types. Machining experiment on AL7075 for impeller is performed to define suitable machining condition, and measurement of surface roughness on machined surfaces depended on each machining condition is performed. By defining suitable machining condition, we should have conclusion as improving the surface quality in the aspect of surface roughness and machined shape of surface.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.1
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• pp.106-113
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• 2010

The most suitable condition for plasma source ion implantation(PSII) was found based on the study of the characteristics of PSIIed tool and machined surfaces. The depth analysis according to the chemical bonding state of elements and surface component elements through the XPS and SIMS, was conducted to find the improved property of the PSIIed surface. Due to the diffusion of PSII, the nitrogen was found up to a depth of about 150nm according to the supplied voltage and ion implanted time. The deep diffusion by nitrogen caused the surface modification, but the formation of oxide component was found due to the residual gas contamination on the surface. Statistical method of ANOVA was conducted to find the effects of spindle speed and feed rate in interaction for machined surface roughness with PSIIed tools. The surface modification was found largely occurred by the nitrogen implanted surface with 2 hours for 27kV, 35kV and 43kV.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.13-18
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• 2012

We investigated the cell activity of controlled titanium surface using various grinding methods including ELID (Electrolytic In-Process Dressing) grinding method. The influence of titanium surface condition by each grinding process on the cell activity was evaluated by ALP activity of MSC(Mesenchymal Stem Cells). The ALP activity of controlled surface by ELID grinding process using # 2000 wheel was higher than that of other titanium surface. The morphological, chemical properties of machined surface by grinding method was observed using various analytical method.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.12
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• pp.120-126
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• 2002

The needs of ultra-precisely machined parts are increasing more and more. But the experimental data required to ultra precision machining of nonferrous metal is insufficient. The behavior of cutting in micro cutting area is different from that of traditional cutting because of the size effect. Copper is widely used as optical parts such as LASER reflector's mirror and multimedia instrument. In experimental, after oxygen-free copper is machined by ultra precision machine with natural mono crystal diamond tool (NCD) and synthetic poly crystal diamond tool (PCD), we compared chip formation and tool's wear according to used tool. Also, we researched optimized cutting condition with the results measured according to cutting condition such as spindle speed, feed rate and depth of cut. As a result, the optimal working condition that makes good surface roughness is obtained. The surface roughness is good when spindle speed is above 80 m/min, and feed rate is small and depth of cut is above 0.5 ${\mu}{\textrm}{m}$. In cutting of klystron anode and cavity 3.2 nmRa of surface roughness is obtained.

• Proceedings of the KWS Conference
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• 1995.10a
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• pp.214-217
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• 1995

In order to investigate characteristics of surface fatigue crack propagation from a pit shaped surface defect which frequently exists near weld joints, SS400 steel with thickness of 12mm, which generally used for structure members, was submerged-arc welded with butt type and machined for both surface. The weld joints were devided into 5 regions, weld metal, boundary between heat affected zone (HAZ), HAZ, boundary between HAZ and base metal, and base metal. Specimens from each region were machined for a pit shaped initial surface defect with aspect ratio of 2. characteristics of surface fatigue crack por pagation from the defect under the same loading condition were compared and discussed.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.3
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• pp.99-103
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• 1998

The curved surface machined by plate end mill causes a excess non-cutting volume, in these cases ball end mill is used for the curved surfaces. This study is aimed to obtain the optimum cutting conditions of various cutting speed, table speed, tool diameter, radius of curvature roughness on the conditions of various cutting speed, tool diameter, radius of curvature when machining the curved surface using the ball end mill. After designing curve rates, obtaining NC data by CAD/CAM system through CC-Cartesian method and transferred the data through DNC system, we machined the specimens by the CNC machining center, The surface roughness of specimens was measured by surface roughness tester and CNC 3D coordinate measuring machine. The cutting condition were the same as follow velocity; 15, 20, 25 30m/min, feed rate;40, 60, 80, 100m/min and radius of curvature; 30,40,50,60mm, tool diameters; ø8, ø12, ø16, ø 20mm. Analizing the working results, we can acquire the optimum cutting condition of curved specimen at the cutting velocity of 20~25m/min and the feed rate of 80mm/min. As the same cutting condition the best surface roughness was showed at ø16mm of the tool diameter. But the tool diameter was smaller than ø8mm. we could improve for the surface roughness by controlling the cusp.