• 한국공작기계학회논문집
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• 제17권4호
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• pp.112-118
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• 2008

In order to meet the optical performance in the process of the micro lens manufacturing with plastics, it is important to embody accuracy in shape and surface roughness to the intended design. Since it is difficult to machine exactly the mold core of lens fit to the designed shape, in this paper, a simple program using MATLAB is developed for shape correction of the mold core after first machining it. This program evaluates correction parameters(aspheric coefficients and curvature) and generates aspheric NC data for compensating the core surface in prior machining process. The program provides the way to manufacture plastic injection molding lens with aspheric shape of high precision, and is expected to be effective for correction and to shorten the processing time.

• 대한기계학회논문집A
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• 제29권2호
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• pp.333-340
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• 2005

Feedrate is one of the factors that have the significant effects on the productivity, qualify and tool life in the cutting mechanism as well as cutting velocity, depth of cut and width of cut. In this study, in order to realize the high-efficient machining, a new feedrate optimization method is proposed based on the concept that the optimum feedrate can be derived from the allowable cutting power since the cutting power can be predicted from the cutting parameters as feedrate, depth of cut, width of cut, chip thickness, engagement angle, rake angle, specific cutting force and so on. Tool paths are extracted from the original NC program via the reverse post-processing process and converted into the infinitesimal tool paths via the interpolation process. And the novel NC program is reconstructed by optimizing the feedrate of infinitesimal tool paths. Especially, the fast feedrate optimization is realized by using the Boolean operation based on the Goldfeather CSG rendering algorithm, and the simulation results reveal the availability of the proposed optimization method dramatically reducing the cutting time and/or the optimization time. As a result, the proposed optimization method will go far toward improving the productivity and qualify.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2001년도 춘계학술대회 논문집
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• pp.1004-1007
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• 2001

This paper presents the experimental results to verify the environmental consciousness with economic balances due to cutting fluid behaviors, effectiveness in machining process. Even though cutting fluid improves the machined part quality through the cooling and lubracating effects, its environmental impact is also increased according to the cutting fluid usage. Because cutting fluid are used by experience than science on shop floors, its environmental impact are more serious to human health hazard, shop floor environments. In this study a few cutting parameters are adopted as the machinability index (i.e. ; tool wear and surface roughness), and aerosol mist diffusion rate of cutting fluid as the environment consciousness index. These indeces are analyzed quantitatively via a few experiements. The results of this study can be facilitate the optimization of cutting fluid usage in achieving a balanced environmental consciousness consideration with economic view.

• International Journal of Precision Engineering and Manufacturing
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• 제9권4호
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• pp.3-10
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• 2008

Micro-electrical discharge machining (micro-EDM) is an effective method for machining all types of conductive materials regardless of hardness. Since micro-EDM is an electro-thermal process, the energy supplied by the pulse generator is an important factor in determining the effectiveness of the process. In this study, an investigation was conducted on the micro-EDM of tungsten carbide (WC) to compare the performance of transistor and resistance/capacitance (RC) pulse generators in obtaining the best quality micro-hole. The performance was measured by the machining time, material removal rate, relative tool wear ratio, surface quality, and dimensional accuracy. The RC generator was more suited for minimizing the pulse energy, which is a requirement for fabricating micro-parts. The smaller-sized debris formed by the low-discharge energy of RC micro-EDM could be easily flushed away from the machined zone, resulting in a surface free of burrs and resolidified molten metal. The RC generator also required much less time to obtain the same quality micro-hole in WC. Therefore, RC generators are better suited for fabricating micro-structures, producing good surface quality and better dimensional accuracy than the transistor generators, despite their higher relative tool wear ratio.

• Journal of Welding and Joining
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• 제28권6호
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• pp.35-39
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• 2010

Generally, ceramic material is very difficult to machine due to high strength and hardness. However, ceramic material can be machined at high temperature by plastic flow as metallic material due to the deterioration of the grain boundary glassy phase. Recently, a new method was developed to execute cutting process with CBN cutting tool by local heating of surface with laser. There are various parameters in LAM because it is a complex process with laser treatment and machining. During laser assisted machining, high power results in reducing of cutting force and increasing tool life, but excessive power brings oxidation of the surface. The effect of laser power, feed rate, cutting depth and etc. were investigated on the life of cutting tool. Chips were observed to find out suitable machining conditions. Chips of SSN had more flow-types than HIPSN. It means SSN is easier to machining. The life of cutting tool was increased with increasing laser power and decreasing feed rate and cutting depth.

• 청정기술
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• 제2권2호
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• pp.165-175
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• 1996

절삭가공 공정에 있어서 절삭유제는 환경영향이 가장 큰 요인들 중의 하나이다. 현재의 기술수준에서 환경영향을 줄이기 위한 공정개선의 방법으로 유제의 환경부하에 대한 평가 및 저부하 유제로의 사용대체가 있다. 본 논문에서는 기존의 절삭성을 바탕으로한 절삭유제의 선택방법과 환경영향을 고려한 선택방법을 비교하여 절삭유제의 선택기준을 제시하고 환경부하의 평가방법으로 AMP 방법을 소개한다. 중절삭이며 저속가공인 드릴링가공을 통하여 절삭성과 환경영향을 함께 고려한 절삭유제의 선택과정을 예시한다. 절삭가공의 물질수지를 고려하여 다섯가지의 환경영향의 평가요소를 선정하고 한국공업규격의 다섯가지의 절삭유제를 비교한다. 비수용성 절삭유제가 성능 뿐만 아니라 환경적인 면에서도 수용성 유제에 비하여 우수한 결과를 보여주었다.

• Advances in materials Research
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• 제1권2호
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• pp.129-146
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• 2012

Polycrystalline diamond is an ideal material for parts with micro-holes and has been widely used as dies and cutting tools in automotive, aerospace and woodworking industries due to its superior wear and corrosion resistance. In this research paper, the modeling and simultaneous optimization of multiple performance characteristics such as material removal rate and surface roughness of polycrystalline diamond (PCD) with ultrasonic machining process has been presented. The fuzzy logic and taguchi's quality loss function has been used. In recent years, fuzzy logic has been used in manufacturing engineering for modeling and monitoring. Also the effect of controllable machining parameters like type of abrasive slurry, their size and concentration, nature of tool material and the power rating of the machine has been determined by applying the single objective and multi-objective optimization techniques. The analysis of results has been done using the MATLAB 7.5 software and results obtained are validated by conducting the confirmation experiments. The results show the considerable improvement in S/N ratio as compared to initial cutting conditions. The surface roughness of machined surface has been measured by using the Perthometer (M4Pi, Mahr Germany).

• 한국공작기계학회논문집
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• 제16권5호
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• pp.77-83
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• 2007

The study on damaged layer is necessary for machinability improvement in micro machining. The damaged layer in metal cutting is derived from plastic deformation and transformation of metal structure. The damaged layer affects micro mold life and micro machine parts. In this study, the damaged layer of micro machined surface of copper is evaluated according to various machining condition. The damaged layer structure and metallurgical characteristics are measured by optical microscope, and evaluated by cutting forces and surface roughness. The scale of this damaged layer depends on cutting process parameters and machining environments. By experimental results, depth of damaged layer was increased with increasing of cutting depth, also the damaged layer is less occurred in down-milling compared to up-milling during micro endmilling operation.

• Journal of Computational Design and Engineering
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• 제1권2호
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• pp.128-139
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• 2014

This study investigates the effects of machining parameters as they relate to the quality characteristics of machined features. Two most important quality characteristics are set as the dimensional accuracy and the surface roughness. Before any newly acquired machine tool is put to use for production, it is important to test the machine in a systematic way to find out how different parameter settings affect machining quality. The empirical verification was made by conducting a Design of Experiment (DOE) with 3 levels and 3 factors on a state-of-the-art Cincinnati Hawk Arrow 750 Vertical Machining Center (VMC). Data analysis revealed that the significant factor was the Hardness of the material and the significant interaction effect was the Hardness + Feed for dimensional accuracy, while the significant factor was Speed for surface roughness. Since the equally important thing is the capability of the instruments from which the quality characteristics are being measured, a comparison was made between the VMC touch probe readings and the measurements from a Mi-tutoyo coordinate measuring machine (CMM) on bore diameters. A machine mounted touch probe has gained a wide acceptance in recent years, as it is more suitable for the modern manufacturing environment. The data vindicated that the VMC touch probe has the capability that is suitable for the production environment. The test results can be incorporated in the process plan to help maintain the machining quality in the subsequent runs.

• 한국기계가공학회지
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• 제13권4호
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• pp.56-68
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• 2014

This paper presents an experiment on the modeling, analysis, prediction and optimization of machining parameters used during the turning process of the low-carbon steel known as ST40. The parameters used to develop the model are the cutting speed, the feed rate, and the depth of the cut. The experiments were carried out under various conditions, with three level of parameters and two different treatments for each level (with and without a lubricant), to determine the effects of the parameters on the surface roughness and electric current consumption. These effects were investigated using response surface methodology (RSM). A second-order model is used to predict the values of the surface roughness and the electric current consumption from the results of experiments which collected preliminary data. The results of the experiment and the predictions of the surface roughness and electric current consumption under both treatments were found to be nearly identical. This result shows that the feed rate is the main factor that influences the surface roughness and electric current consumption.