• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.4
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• pp.71-78
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• 2020

The rotary feed axes of a 5-axis machine tool can increase the freedom of the tool posture, while reducing feed speed and rigidity. In addition, as a ball-end mill is inevitably used during machining by rotational feed, the step-over length is reduced compared to the flat-end mill, thereby reducing the material removal rate. Therefore, this study attempts to improve the material removal rate, feed speed, and machining stability using the corner radius flat-end mill and a fixed controlled machining method for the rotary feed axes during roughing. In addition, the tapered ball-end mill and simultaneously controlled machining method for the rotary feed axes were used for finishing to improve the propeller's 5-axis machining efficiency by enhancing the surface quality. In order to create the tool path effectively and easily, we propose a specific approach for using the propeller's geometric properties and evaluate the effectiveness of the proposed method by comparing it with the method of the dedicated module.

• Korean Journal of Computational Design and Engineering
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• v.9 no.1
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• pp.35-43
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• 2004

It is well known that the five-axis machining has advantages of tool accessibility and machined surface quality when compared with conventional three-axis machining. Traditional researches on the five-axis tool-path generation have addressed interferences such as cutter gouging, collision, machine kinematics and optimization of a CL(cutter location) or a cutter position. In the paper it is presented that optimal CL data for a face-milling cutter moving on a tool-path are obtained by incorporating TSS(tool swept surface) model. The TSS model from current CL position to the next CL position is constructed based on machine kinematics as well as cutter geometry, with which the deviation from the design surface can be computed. Then the next CC(cutter-contact) point should be adjusted such that the deviation conforms to given machining tolerance value. The proposed algorithm was implemented and applied to a marine propeller machining, which proved effective from a quantitative point of view. In addition, the algorithm using the TSS can also be applied to avoid cutter convex interferences in general three-axis NC machining.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.3
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• pp.63-70
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• 2020

Two rotational motions of the 5-axis machine tool maximize the degree of freedom of the tool axis vector, which improves tool accessibility; however, this lowers feed speed and rigidity, which impairs machining stability. In addition, cutting efficiency is lowered when compared with a flat end mill because typically, the ball-end mill is used when machining by rotational motion. This study increased cutting efficiency by using a corner radius flat end mill during impeller roughing. Furthermore, we proposed a fixed controlled machining of the rotary motion using geometric shape information to improve the feed speed and machining stability. Finally, we proposed a finishing tool path generation method using a vector net to increase the convenience and practicality of tool path generation. To verify its effectiveness, we compared the machining time, shape accuracy, and surface quality of the proposed method and an existing dedicated module.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.10
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• pp.45-51
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• 2010

Electrical discharge drilling (ED-drilling) is a widespread machining method used to bore small holes with a high aspect ratio. This paper presents additional methods by which ED-drilling can improve machining speed, tool wear, and machined surface quality. Firstly, for high machining speed, and low tool wear, a new-type electrode that was ground on one side or both sides of the cylindrical electrodes was suggested to expel debris. The debris which is generated during the machining process can cause sludge deposition and secondary discharge problems: major reasons to decrease machining speed. This new-type electrode also reduced tool wear that was due to the decrease of unstable discharge in a machining gap by helping to expel waste water and debris from the gap. Secondly, to improve the machined surface roughness, an electrolyzation process was included after drilling. This process made the machined surface smooth by means of an electrochemical reaction between an electrode and a workpiece. In this study, the machining speed, electrode wear, and surface roughness were improved by the newtype electrode and the electrolytic process.

• 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.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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• pp.123-129
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• 2022

Quartz (SiO2) has high abrasion and heat resistances and excellent chemical and mechanical properties; therefore, it is used in various industries, such as machinery, chemistry, optics, and medicine. Quartz is a high-hardness and brittle material and is classified as the topmost difficult-to-cut material, which is because of the cracking or chipping at the edge during processing. Corner wear, such as cracks and chippings that occur during cutting, is a major cause for the deterioration in the machining quality. Therefore, many researchers are investigating various techniques to process quartz effectively. However, owing to the mechanical properties of quartz, most studies have been conducted on grinding, micromachining, and microdrilling. Few studies have been conducted on quartz processing. The purpose of this study was to analyze the machining characteristics according to the machining factors during the slot machining of quartz using a cubic boron nitride (CBN) tool and to select the optimal machining conditions using the Taguchi method. The machining experiment was performed considering three process variables: the spindle speed, feed rate, and depth of cut. The cutting force and surface roughness were analyzed according to the processing conditions.

• Design & Manufacturing
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• v.16 no.3
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• pp.22-27
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• 2022

The demand for new processing technology that can improve productivity is increasing in industries that require large-scale and various products. In response to this demand, a robot machining system with flexibility is required. Because of the low rigidity of the robot, the robot machining system has a large error during machining and is vulnerable to vibration generated during machining. Vibration generated during machining deteriorates machining quality and reduces the durability of the machine. To solve this problem, a stage for fixing the spindle during machining is required. In order to compensate for the robot's low rigidity, a system combining a piezoelectric actuator for generating a large force and a guide mechanism to actuate with a desired direction is required. Since the rigidity of flexible hinges varies depending on the structure, it is important to optimal design the flexible hinge and high-rigidity system. The purpose of this research is to make analytic model and optimize a flexible hinge and to design a high rigidity stage. In this research, to design a flexible hinge stage, a concept design of system for high rigidity and flexure hinge modeling is carried out. Based on analytic modeling, the optimal design for the purpose of high rigidity is finished and the optimal design results is used to check the error between the modeling and actual simulation results.

• Advances in materials Research
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• v.1 no.2
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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).

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.6
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• pp.41-48
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• 2015

Stainless steel mesh has been used as a filter in various fields, including domestic, medical, etc. However, the surface before machining may have an adverse effect the product quality and performance because it is not smooth. Especially, adsorbed impurities in the surface result in difficulty in cleaning. Therefore, in this paper, we propose an improved surface quality through electrochemical polishing (ECP). Two electrodes, composed of STS304 (anode) and copper (cathode) underwent machining with two conditions according to polishing time and current density. As the polishing time and current density increase, the surface of curvature decreases, and roughness and material removal rate (MRR) improves. The machined surface roughness and image were obtained through the atomic force microscope (AFM) and stereoscopic microscope. The study also analyzed hydrophilic effect through contact angles. This obtains corrosion resistance, smoothness, hydrophilic property, etc.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.214-219
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• 2001

One of the major limitations of productivity and quality in metal cutting is the machining accuracy of machine tools. The machining accuracy is affected by geometric errors, thermally-induced errors, and the deterioration of the machine tools. Geometric and thermal errors of machine tools should be measured and compensated to manufacture high quality products. In metal cutting, the machining accuracy is more affected by thermal errors than by geometric errors. In this study, the compensation device and temperature-based algorithm have been presented in order to compensate thermal error of machine tools under the real-time. The thermal error is modeled by means of angularity errors of a column and thermal drift error of the spindle unit which are measured by the touch probe unit with a star type styluses, a designed spherical ball artifact, and five gap sensors. In order to compensate thermal characteristics under several operating conditions, experiments performed with five gap sensors and manufactured compensation device on the horizontal machining center.