• Transactions of Materials Processing
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• v.23 no.1
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• pp.23-28
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• 2014

The aspect ratio of a hole is defined as the ratio of the thickness to the diameter of the sheet metal. Most holes in the sheet metal industry are made by piercing. However, for thick sheets, which have an aspect ratio greater than 2, a machining process like drilling instead of piercing is usually used to make holes. In the current study, piercing, which is a shearing process, is evaluated to punch a hole with a high aspect ratio by using a newly designed die set-up. The piercing die was manufactured to prevent the punch from buckling and also to improve the alignment between the die components. An aluminum alloy sheet was selected for the experiments. The influence of several process parameters such as sheet thickness, clearance and stripping force were investigated. Experimentally, a hole with an aspect ratio of 5 was pierced. The resulting hole had a clean surface and the dimensional accuracy of pierced hole was considerably improved with decreasing clearance between punch and die. It is also shown that the larger penetration depth of the effective sheared surface can be achieved for high aspect ratio piercing relative to conventional piercing with a low aspect ratio.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.3
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• pp.63-68
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• 2017

In order to process more complicated and higher-precision parts, generally, an additional axis for a machine tool is needed which was an approach to minimize the cost of tool modification. A table with a rotary reducer that can rotate through the axis of the gear system was employed to a machine tool to achieve the purpose of adding an extra motion axis. In general, the motion of the rotary reducer is driven by a worm/wheel or helical gear system, which is different from the hypoid helical gear structure that used in this research. Reliability of guarantee of high accurancy throughout the whole life cycle is on of the critical factors to evaluate a rotary reducer in this field. In this paper, in order to evaluate life-time of rotary reducer, a low-cost accelerated life test was developed to satisfy the demands of clients.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.1038-1043
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• 1997

To adapt the neural network proess for the purpose of determination of optimal utting onditions (optimal cutting speed and feed rate), some selection strategies for the machining factors are necessary, which is considered planning cutting process. In this case, factors that have both nonlinearity and strong relationship must be selected. Although tool grade and chemical properties of workpiece material have strong effect to cutting speed, it's not easy to find a analytic relation between them. In this paper, a mathematical method for determining the optimal amount of cutting (depth of cut, feed rate) is presented by tool goemetry and heat generation during cutting process. And various tool grade and workpiece material groups ase classified based on its chemical properties. Thier chemical composition and hardness are used as input pattern for neural network learnig. The result of learning shows the relationship between tool grade and workpiece material and it is proved that it can be used as a sub-system for automatic process planning system.

• International Journal of Precision Engineering and Manufacturing
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• v.6 no.3
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• pp.24-28
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• 2005

Stress state of chip formation zone is one of the main problems in metal cutting mechanics. In two-dimensional case this process is usually considered as consistent shears of work material along one of several shear surfaces, separating chip from workpiece. These shear planes are assumed to be trajectories of maximum shear stress forming corresponding slip-line field. This paper suggests a new approach to the constriction of slip-line field, which implies uniform compression in chip formation zone. Based on the given model it has been found that imaginary shear line in orthogonal cutting is close to the trajectory of maximum normal stress and the problem about its determination has been considered as well. It has been shown that there is a second central slip-line field inside chip, which corresponds well to experimental data about stress distribution on tool rake face and tool-chip contact length. The suggested model would be useful in understanding mechanistic problems in machining.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.2
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• pp.199-205
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• 2014

This research focuses on the development of an interrogator that operates and measures fiber Bragg grating(FBG) multiplexing sensor probes for accurate-measurement of the blade deflection in a wind power generator. We designed and fabricated an optical source and spectrum module for the interrogator. Additionally, we verified the wavelength repeatability within 0.001 nm and the wavelength stability within 1 pm of the optical source, and we experimentally determined that the wavelength scanning range was about 44.4 nm. The FBG sensor with 2 nm resolution can be extended to a performance-efficient system that measures more than 20 sensors. The implemented interrogator has 0.141 nm wavelength variations corresponding to an ambient temperature range of $0^{\circ}C$ to $70^{\circ}C$. The measurement error can be easily reduced by employing a temperature compensation algorithm. In this study, we quantitatively confirmed the accuracy and operating stability of the interrogator.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.101-108
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• 2016

Endmill fillet cutting at the corner was conducted with the online measurement of cutting forces and tool deflection by a tool dynamometer and an eddy current sensor system. The profile of the machined surface was also compared with the CAD profile with a Coordinate Measuring Machine (CMM) and CALYPSO software. It was found that the end mill cutter with four blades has a better surface profile than that with two blades, and the cutting forces and tool deformation were increased as the cutting speed was increased. When the tool located at the degree $45^{\circ}$ corner was found to conduct the maximum cutting force than started to the point of the workpiece. As it was compared with the CMM and ANOVA analysis result in the case that the cutting force and tool deformation was the maximum, it was found that the result was affected by the spindle speed and the number of blades.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.10
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• pp.45-52
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• 1999

The online realtime positioning error compensation system 'SKY-PACS' is developed to correct geometric errors, thermal errors and tool deflection errors induced by cutting forces on the vertical machining center. 'SKY-PACS' communicates position commands and position compensation signals with the CNC controller at 100Hz, which is CNC control frequency. So the compensation procedure can be applied during axis movement. Using 'SKY-PACS', Maximum 1 axis positioning accuracy was corrected from 5{\mu}m$ to 2{\mu}m$and the squareness error of X-Y table was corrected from 51{\mu}m$/m to below 4{\mu}m$/m. The error compensation under the cutting condition is carried out by ISO10791-7. And the measurement of test-pieces shows that the roundness is corrected rom 8{\mu}m$ to below 5{\mu}m$.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.12
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• pp.25-33
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• 2003

A burr has been defined as undesirable projection of material formed as a result of plastic flow from a cutting or shearing operation. It is unavoidable in all kinds of machining operation. As a result, burr makes troubles on manufacturing process due to deburring cost, quality of products and productivity. In this study, the primary interest is about exit burr. The burr formation mechanism in each type of burr is classified. Data bases are developed to predict burr formation result. In the milling operation, we develop an algorithm to analyze the burr formation mechanism by the geometrical analysis on the multi featured workpiece with multi cutting path. The algorithm includes three steps, i. e., the feature identification, the cutting condition identification, and the analysis on exit burr formation. We can predict which portion of workpiece would have the exit burr in advance so that we can manage to find a way to minimize the exit burr formation in an actual cutting. Also, this algorithm can be implemented in a commercial CAM package so that we can simulate the NC code to review the burr formation in advance.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.91-94
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• 2005

With increasing demands for large-scale micro-optical components in the field of digital display, the establishment of large-scale fabrication technology fur polymeric patterns has become a priority. The starting point of any polymer replication process is the mold, and the mold often has flat surface. However, It is very hard to replicate large-scale micro patterns using the flat mold, because the cost of large-scale flat mold was very high, and some uniformity and releasing problems were often occurred in large scale flat molding process. In this study, a UV roll imprinting system to overcome the financial and fabrication issues of large-scale pattern replication process was designed and constructed. As a practical example of the system, a lenticular lens with radius of curvature of $223{\mu}m$ and pitch of $280{\mu}m$, which was used to provide wide viewing angle in projection TV, was designed and fabricated. The roll stamper was fabricated using direct machining process of aluminum roll base. Finally, the shape accuracy and uniformity of roll imprinted lenticular lens sheet were measured and analyzed.

• The Journal of Korea Robotics Society
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• v.11 no.4
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• pp.248-255
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• 2016

Machining error makes the uncertainty of dimensional accuracy of the kinematic structure of a parallel robot system, which makes the uncertainty of kinematic accuracy of the end-effector of the parallel robot system. In this paper, the tendency of trajectory tracking error caused by the tolerance of design parameters of the parallel robot is analyzed. For this purpose, all the position errors are analyzed as the manipulator is moved on the target trajectory. X, Y, Z components of the trajectory errors are analyzed respectively, as well as resultant errors, which give the designer of the manipulator the intuitive and deep understanding on the effects of each design parameter to the trajectory tracking errors caused by the uncertainty of dimensional accuracy. The research results shows which design parameters are critically sensitive to the trajectory tracking error and the tendency of the trajectory tracking error caused by them.