• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 춘계학술대회 논문집
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• pp.581-582
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• 2006

This paper presents an integrated machining error compensation method based on PNN(Polynomial Neural Network) approach and inspection database of OMM(On-Machine-Measurement) system. To efficiently analyze the machining errors, two machining error parameters are defined and modeled using the PNN approach, which is used to determine machining errors for the considered cutting conditions. Experiments are carried out to validate the approaches proposed in this paper. In result, the proposed methods can be effectively implemented in a real machining situation, producing much fewer errors.

• 한국기계가공학회지
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• 제18권10호
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• pp.42-47
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• 2019

Helical machining is an efficient method for machining holes using an endmill. In this study, a surface roughness prediction model was constructed for improving the productivity of hole machining. Experiments were conducted to form holes by the helical machining of AL6061-T4 aluminum sheets and correlation analysis was performed to examine the relationships between the variables based on the measured results. Meanwhile, a regression analysis technique was used to construct and evaluate the prediction model. Through these analyses, the parameter which has the greatest influence on the surface roughness when the hole is formed by the helical machining is the feed, followed by the number of revolutions of the endmill. Moreover, for the axial feed of the endmill, it was concluded that the influence of the surface roughness is small compared to the other two parameters but it is a factor worth considering to improve the accuracy when constructing the predictive model.

• 한국생산제조학회지
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• 제21권4호
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• pp.556-562
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• 2012

Micro electrical discharge machining (${\mu}EDM$) has been used for non-conventional material removal. One drawback of ${\mu}EDM$ is low productivity. In this study, we tried to find the optimal machining conditions to manufacture the micro hole with an optimal machining time without loss of accuracy. Taguchi method was used to figure out the relation between machining parameters and characteristics of the process. It was found that the electrode wear, the entrance and exit clearance gave a significant effect on the diameter of the micro hole when the diameter of the electrode was identical. Grey relational analysis was used to determine the optimal machining condition for minimum machining time without loss of accuracy. The obtained optimal machining condition was the input voltage of 80V, the capacitance of 680pF, the resistance of $500{\Omega}$, the feed rate of $1.5{\mu}m$/s and the spindle speed of 2900rpm. The machining time was reduced to 48% without loss of accuracy under the optimal machining condition.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2003년도 춘계학술대회 논문집
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• pp.636-639
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• 2003

It is difficult to machine below 10 micrometers by conventional machining methods, such as micro-EDM. However, ultra micro machining using focused ion beam(FIB) is able to machine to 50 nanometers. In addition, 3 dimensional structures can be made by a combination of FIB and CVD to the level of 10 nanometers. Die ＆ moulds techniques are better than one-to-one machining techniques in the mass production of ultra size structures, in regards to production costs. In this case, the machining precision of die ＆ moulds affects produced parts. Also, it is advantageous to machine die ＆ moulds to the 10 micrometer level by FIB technique rather than other techniques. In this paper, the grooving characteristics for die ＆ mould materials by FIB were carried out experimentally in order to compare the machining characteristics of FIB with conventional machining methods. The results showed that the machining parameters and the scanning path of FIB affects the precision. The machined width and depth of the groove varied depending on the required depth due to the redeposition of the sputtered ion material accumulating on both the bottom and the side of the wall.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2002년도 금형가공 심포지엄
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• pp.245-252
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• 2002

Ultrasonic machining technology has been developed over recent years for the manufacture of cost-effective and quality-assured precision parts for several industrial application such as optics, semiconductors, aerospace, and automobile. Ultrasonic machining process is an efficient and economical means of precision machining of ceramic materials. The process is non-thermal, non-chemical and non-electric md hardly creates changes to the mechanical properties of the brittle materials machined. This paper describes the characteristics of the micro-hole of $Al_2O_3$ by ultrasonic machining with tungsten carbide tool. The effects of various parameters of ultrasonic machining, including abrasives, machining force and pressure, on the material removal rate, hole quality, and tool wear presented and discussed. The ultrasonic Machining of micro-holes in ceramics has been under taken and the machining mechanism in the ultrasonic machining of ceramics based on the fracture-mechanics concept has been analyzed.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2000년도 추계학술대회논문집 - 한국공작기계학회
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• pp.343-348
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• 2000

The term‘High Speed Machining’has been used for many years to describe end milling with small diameter tools at high rotational speeds. typically 10,000 - 100,000 rpm. The process was applied in the aerospace industry for the machining of light alloys, notably aluminium. In recent years, however, the mold and die industry has begun to use the technology for the production of components, including those manufactured from hardened tool steels. And the end-mill is an important tool in the milling process. A typical examples for the end mill is the milling of pocket and slot in which a lot of material is removed from the workpiece. Therefore the proper selection of cutting parameters for end milling is one of the important factors affecting the cutting cost. The one of the advantages of HSM is cutting thin-wall part of light alloy like Al (thinkness about 0.3mm). In this paper, firstly, we study characteristics of HSM, and then, we choose the optimal parameters(cutting forces) and investigate various machining strategies to cut thin-wall part by experiment.

• 대한기계학회논문집A
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• 제27권12호
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• pp.2085-2091
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• 2003

An ultrasonic machining process has been known as efficient and economical means fer precision machining of glass or ceramic materials. However, because of its complexity, the mechanism of the machining process is still not well understood. Therefore, it is hard to optimize the process parameters effectively. The conventional ultrasonic machining which uses the abrasive slurry only, furthermore, is time-consuming and gives the relatively rough surface. In order to increase the material removal rate and improve the integrity of the machined surface, we have introduced the novel ultrasonic machining technique, Chemical-assisted UltraSonic Machining(CUSM). The desktop-style micro ultrasonic machine has been developed and the z-axis feed is controlled by the constant load control algorithm. To obtain the chemical effects, the low concentration HF(hydrofluoric acid) solution, which erodes glass, added to alumina slurry. Through various experiments and comparison with conventional results, the superiority of CUSM is verified. MRR increases over 200%, the surface roughness is improved and the machining load decreases dramatically.

• International Journal of Precision Engineering and Manufacturing
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• 제9권4호
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• pp.74-78
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• 2008

High-speed tool steels are extensively used in tooling industries for manufacturing cutting tools, forming tools, and rolls. Electrical discharge machining (EDM) has been found to be an effective process for machining these extremely hard and difficult-to-cut materials. Extensive research has been conducted to identify the optimum machining parameters for EDM with different tool steels. This paper presents a fundamental study of the surface characteristics of SKH-51 tool steel machined by micro-EDM, with particular focus on obtaining a better surface finish. An RC pulse generator was used to obtain a better surface finish as it produces fine discharge craters. The main operating parameters studied were the gap voltage and the capacitance while the resistance and other gap control parameters were kept constant. A negative tungsten electrode was used in this study. The micro-EDM performance was analyzed by atomic force microscopy to determine the average surface roughness and the distance between the highest peak and lowest valley. The topography of the machined surface was observed using a scanning electron microscope and a digital optical microscope.

• 한국윤활학회:학술대회논문집
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• 한국윤활학회 2002년도 proceedings of the second asia international conference on tribology
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• pp.259-260
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• 2002

In this paper, electrical discharge machined (EDM) surfaces machined with various machining parameters are characterized and simulated. Three-dimensional surface topography of EDM surfaces are measured by a stylus instrument. Surface topography is characterized with auto-correlation coefficient and height probability density functions. Then, EDM surfaces are modeled and computer-simulated by using the non-causal 2-D auto-regressive model. Simulation results show that EDM surfaces are characterized well by a few parameters.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2004년도 추계학술대회 논문집
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• pp.1418-1423
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• 2004

High speed machining experiment on the heat-treated mold steel(STAVAX and CALMAX of hardness HRc 53) is carried using TiAlN coated ball endmill. Tool life and wear characteristics under the various machining parameters and cooling methods are investigated. Effect of cooling method on life and wear of the tool was compared. For most cases, tool life was not determined by the amount of wear but by th chipping on the cutting edge. It is found that tool manufacturer's cutting parameters generally agrees with the results of this experiment.