• Journal of the Korean Society for Precision Engineering
• /
• v.15 no.4
• /
• pp.141-147
• /
• 1998

A plastically deformed layer in the precision machined surface affects in various forms the physical properties of machined components such as the fatigue strength, the dimensional instability, microcracks and the stress corrosion cracking. These physical properties, so called surface integrity, are very important for designing highly stressed and critically loaded components. Typical plastic strains in the precision machined surface are very difficult to measure, since they are located within a very short distance from the surface and they change very rapidly. A new way is suggested to determine the residual strain in plastically deformed materials by analyzing the plastically deformed layer after a subsequent recrystallization process. This investigation is to explore a new technique for measuring plastic strain in machining applications, and in particular, to and the effect of cutting parameters(rake angle, depth of cut, specific cutting energy), on the plastic strains and strain energy.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.19 no.2
• /
• pp.295-300
• /
• 2010

Inconel 718 alloy, widely used as material of aircraft engine, has a good mechanical property in high temperature, strong anti-oxidation characteristics in oxidated current over $900^{\circ}C$, and also is not easily digested in the air containing sulfur, therefore, its usage as mechanical component is expanding rapidly. Even though Inconel alloy 718 is difficult to machine, it requires highly precise processing/machining to sustain its component quality of high accuracy. In this paper, general turning operation conditions arc tested to select the best cutting process condition by measuring surface roughness through implementing experiments with orthogonal array of cutting speed, feeding speed and cutting depth as processing parameters based on the Taguchi method. Optimal turning operation conditions are extracted from the proposed experimental models.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1996.11a
• /
• pp.9-14
• /
• 1996

The deflection of an end mill is very important in machining process and cutting simulation because it affects directly workpiece accuracy, cutting force, and chattering. In this study, the deflection of the end mill was studied both experimentally and by using finite element analysis. And the moment of inertia of radial cross sections of tile helical end mill is calculated for the determination of the relation between cross section and rigidity of tile tools. Using tile Bernoulli-Euler beam and and the concept of equivalent diameter, a deflection model is established, which includes most influence from tool geomety parameters. It was found that helix angle attenuates the rigidity of the end mill.

• Journal of the Korean Society for Precision Engineering
• /
• v.22 no.7 s.172
• /
• pp.79-87
• /
• 2005

This paper summarizes the work on the development of a simulation program for modelling the process of machining quasi-three dimensional shape with the excimer laser beam on a constantly moving polymers. Relatively simple masks of rectangle, triangle and half circle shape are considered. The etching depth is calculated by considering the number of laser pulses irradiated on the specimen surface. It was found that similar shapes as experimental results can be obtained by choosing suitable parameters of moving velocity, moving distance and mask sizes.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.10
• /
• pp.135-140
• /
• 1997

The detection of cutting tool states in machining is important for the automation. The information of cutting tool states in metal cutting process is uncertain. Hence a industry needs the system which can detect the cutting tool states in real time and control the feed motion. Cutting signal features must be sifted before the classification. In this paper the Fisher's linear discriminant function was applied to the pattern recognition of the cutting tool states successfully. Cutting conditions and cutting force para- meters have shown to be sensitive to tool states, so these cutting conditions and cutting force paramenters can be used as features for tool state detection.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.05a
• /
• pp.347-349
• /
• 2009

Unmanned helicopters are needed in various fields such as monitoring system, agriculture and forest fire. Swash plate is a essential part for exact driving of unmanned helicopter. And it is usually produced by machining. In this research, hot forging process of upper swash plate has been studied to improve proof stress against repeated loading of the product. In the forming analysis, design parameters such as effective stress, effective strain and distribution of damage have been considered in the hot forging.

• Journal of the Korean Society for Precision Engineering
• /
• v.13 no.10
• /
• pp.139-145
• /
• 1996

The machining accuracy and performance is largely influenced by the static, dynamic and thermal characteristics of spindle systems in machine tools, because the spindle system is a intermedium for cutting force from tool and machine powef from motor. Large cutting force and power are transmitted by bearing with a point or line contact. So, the spindle system is the static and dynamic weakest point in machine structure. For improvement of static stiffness of spindle system can be changed design parameters, such as diameter of spindle, stiffness of bearing and bearing span. But for dynamic stiffness, the change of the design parameters are not useful. In this paper, the combined bearing arrangement is suggested for high damping spindle system. The combined bearing arrangement is composed of tandem double back to back arrangement type ball bearins and a high damping hydrostatic bearing. The variation of static deflection and amplitude in first natural frequency is evaluated with the location of hydrostatic bearing between front and rear ball bearing. The optimized location of hydrostatic bearing for high static and dynamic stiffness is determined rapidly and exactly using the mode shape and transfer function of spindle. The calculation of damping effect on vibration by unbalance of grinding wheel and pulley in optimized spindle system is carried out to verify the validity of the combined bearing arrangement. Finally, the simulation of grinding process show that the surface roughness of workpiece with high damping spindle system is 60% better than with ball bearing spindle system.

• Steel and Composite Structures
• /
• v.34 no.5
• /
• pp.681-698
• /
• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.

• Transactions of Materials Processing
• /
• v.18 no.2
• /
• pp.150-155
• /
• 2009

A shaft for laser printers has to be produced with high dimensional accuracy of a few micrometers. Most companies produce the shaft, therefore, by machining. These days, forging process is tried to be employed in manufacturing the shaft for productivity. In this study, the dimensional inaccuracy of straightness is studied and the underfill is not focused because the shaft shape is simple and the load capacity of press is sufficient. The straightness and concentricity of the shaft is important for the operation of a laser printer. Many design parameters such as preform shapes, tooling dimensions, forging load, and billet geometries may affect on the dimensional accuracy. In the forging process of shafts, a billet which is cut from wires is used. The billet, therefore, may be a little bit curved but not always straight. The elastic recovery is considered to cause the dimensional inaccuracy. Therefore, the effect of the forging load on the elastic recovery and straightness is investigated through the finite element analyses using DEFORM-3D and ABAQUS.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.1
• /
• pp.110-115
• /
• 2016

The need for high-strength galvanized steel has recently increased because of the increased number of car consumers who want improved efficiency and exterior quality. High-strength galvanized steel with high corrosion resistance improves the durability of products and exterior quality. Furthermore, the gilt of zinc does not come off during machining because of the fine adhesive property of zinc. When these are welded, zinc has a lower melting temperature than iron, so zinc is more quickly vaporized than iron. Vaporized zinc can stick to electrodes, which increases spatter in welding transportation. Created spatter can enter the molten pool and develop into inner defects or blowholes and pits. Scattered spatter sticks to the product, which leads to the secondary cost of spatter removal. Therefore, in this study, comparisons of amounts of spatter generated are conducted according to the composition of shielding gas in the MIG and CMT processes to find optimal welding parameters.