• 한국정밀공학회지
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• 제16권2호통권95호
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• pp.201-210
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• 1999

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 and thermal errors of the machine tools. Therefore, a key requirement for improving te machining accuracy and product quality is to reduce the geometric and thermal errors of machine tools. This study models geometric error for error analysis and develops on-machine measurement system by which the volumetric erors are measured. The geometric error is modeled using form shaping function(FSF) which is defined as the mathematical relationship between form shaping motion of machine tool and machined surface. The constant terms included in the error model are found from the measurement results of on-machine measurement system. The developed on-machine measurement system consists of the spherical ball artifact (SBA), the touch probe unit with a star type stylus, the thermal data logger and the personal computer. Experiments, performed with the developed measurement system, show that the system provides a high measuring accuracy, with repeatability of ${\pm}2{\mu}m$ in X, Y and Z directions.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2003년도 춘계학술대회 논문집
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• pp.1768-1771
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• 2003

Hard turning replaces grinding for finishing process with expectations of higher productivity and demanded surface quality. Especially for the surface roughness as surface quality demanded in finishing process of hard turning, know-how of machining characteristics of hardened materials by cutting force analysis should be accumulated in company with achievement of precision of elements and high stiffness design technology in hard turning. Considering chip formation mechanism of hardened materials, adequate cutting conditions are selected for machining experiments and cutting forces are measured according to cutting conditions. Increase of cutting forces especially thrust force and increase of dynamic instability could occur in hard turning. Analysis of dynamic characteristics of the cutting forces is executed to investigate relation between dynamic instability and surface roughness in hard turning. Investigation on effects of relative motion of machining system generated by vibration due to dynamic instability shows that ultimate surface roughness could be predicted considering relative motion of machining system with geometrical surface roughness.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 춘계학술대회 논문집
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• pp.775-778
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• 2000

Single point diamond turning technique fur optical crystals is reported in this paper. The main factors influencing the machined surface quality are discovered and regularities of machining process are drawn. Optical crystals have found more and more important applications in the field of modern optics. Optical crystals are mostly brittle materials of poor machinability. The traditional machining method is polishing which has many shortcomings such as low production efficiency, poor ability to be automatically controlled and edge effect of the workpiece. SPDT has been widely used in manufacturing optical reflectors of non-ferrous metals such as aluminum and copper which are easy to be machined for their proper ductility. But optical crystals being discussed here are characterized by their high brittleness which makes it difficult to obtain high quality optical surfaces on them. The purpose of cur research is to find the optimum machining conditions for ductile cutting of optical crystals and apply the SPDT technique to the manufacturing of ultra precision optical components of brittle materials. As a result, the cutting force is steady, the cutting force range is 0.05-0.08N. The surface roughness is good when spindle is above 1400rpm. and feed rate is small. The influence of depth of cut is very small.

• Journal of Welding and Joining
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• 제28권3호
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• pp.42-48
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• 2010

Polycarbonate (PC) and Acrylonitrile Butadiene Styrene (ABS) were welded by a combination of a diode laser and a CNC machining center. Laser beam delivered through the transparent PC and was absorbed in an opaque ABS. Polymers were melted and joined by absorbed and conducted heat. Experiments were carried out by varying working distance from 44mm to 50mm for the focus spot diameter control, laser input power from 10W to 25W, and scanning speed from 100 to 400mm/min. The weld bead and cross-section were analyzed for weld quality, and tensile results were presented through the joint force measurement. With focus distance at 48mm, laser power with 20W, and welding speed at 300mm/min, experimental results showed the best welding quality which bead size was measured to be 3.75mm. The shear strength at the given condition was $22.8N/mm^2$. Considering tensile strength of ABS is $43N/mm^2$, shear strength was sufficient to hold two materials. A single process was possible in a CNC machining system, surface processing, hole machining and welding. As a result, the process cycle time was reduced to 25%. Compared to a typical process, specimens were fabricated in a single process, with high precision.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 춘계학술대회 논문집
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• pp.97-101
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• 1996

In this paper, We have studied internal quality incluiding chemical compositions, microscopic structrue and nonmetalic inclusion of test materials. We have analyzed dynamic characteristics of cutting resistence including tensile strength value, hardeness value, impact value etcs. We have compared chip treatments of test materials. In analyzing internal quality, all of test materials have typical ferrite+pearlite structure. But, nonmetallic inclusion have oxide and sulfide inclusion in medium carbon steels, mainly sulfide inclusion is existed in S-free cutting steels. In Ca+S-free cutting steels, calcium aluminate and sulfide complex inclusion, had low-melting points, as deformation of sulfide and oxide inclusion is existed. machining characteristics, cutting resistence is maximum in Ca+S-free cutting steels, minimum in medium carbon steels. Chip treatements are excellent in S-free cutting steels, similar to the Ca+S free cutting steels and medium carbon steels.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 춘계학술대회 논문집
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• pp.1073-1077
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• 1997

In this paper, we have studied internal quality including chemical compositions, microscopic structure and nonmetalic inclusion of test materials. We have analyzed machining characteristics including tensile strength value, impact value, hardness value etcs. Test materials are usd martensitic heat resisting steel, STR11 and STS420J2. The obtined results are as follows : 1. In analyzing internal quality, STR11 and STR420J2 have typical martensite structure and a minute needle-shaped structure. 2. Tensile strength and reduction of area and hardness value are large STR11 than STS420J2. But elongation impact are smaller STR11 than STS420J2. 3. Fracture surface of tensile speciman is ductile in STR11 and STS420J2.

• International Journal of Precision Engineering and Manufacturing
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• 제8권3호
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• pp.14-19
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• 2007

Rapid prototyping (RP) technology can fabricate any 3D physical model regardless of geometric complexity using the layered manufacturing (LM) process. Stereolithography (SL) is the best-known example of RP technology. In general, the surface quality of a raw SL-generated part is unsatisfactory for industrial purposes due to the step artefact created by the LM process. Despite of the increased number of applications for SL parts, this side effect limits their uses. In order to improve their surface quality, additional post-machining finishing, such as traditional grinding, is required, but post-machining is time consuming and can reduce the geometric accuracy of a part. Therefore, this study proposes a post-machining technology combining coating and grinding processes to improve the surface quality of SL parts. Paraffin wax and pulp are used as the coating and grinding materials. By grinding the coating wax only up to the boundary of the part, the surface smoothness can be improved without damaging the surface. Finally, moulding and casting experiments were performed to confirm the suitability of the SL parts finished using the proposed process with rapid tooling (RT) techniques.

• 한국기계가공학회지
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• 제20권1호
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• pp.57-65
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• 2021

With the increased utilization of CAM programs, end-mill processing is most commonly used for machining and metal processing. In particular, hole or shaft machining has high assembly precision, which inevitably leads to high utilization of end mills. However, the analysis of quality characteristics according to the process conditions of end mills is not performed systematically at the site, causing poor quality and productivity. The most influential factor of quality is the runout of the end mill. In this paper, the number of turns of the end mill, number of tool blades, cutting direction, and artificial runout volume were determined to identify the correlation between the epicenter, cylindricality, and surface roughness. Two types of end mills, three levels of runout, three levels of rotational speed, and two cutting directions were considered and 36 rounds of hole processing were conducted. For the analysis of shape characteristics according to the set process variables, the experimental planning method was applied to the measured specimen and the processing characteristics were analyzed according to the runout of the end mill through correlation analysis.

• Design & Manufacturing
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• 제16권3호
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• pp.39-43
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• 2022

In this study, we designed an vibration cutting tool that can achieve improvements such as low cutting force, interrupted chip evacuation and better surface quality of cutting performance to obtain high-quality surface roughness and improvement of tool wear, which is an issue in the machining of high-hardness mold steel. Among the resonance frequency modes of the vibration cutting tool, the bending mode was used to maximize the driving amplitude of the vibration tool tip, and the resonance frequency was confirmed through the finite element method. After measuring the actual resonant frequency of the designed tool using an optical fiber sensor, the cutting force and machining surface of vibration cutting and conventional cutting were compared and analyzed in the turning process of high hardness mold steel (STAVAX). As a result of the experiment, the cutting force was reduced by about 20 % compared to the conventional cutting process, and the surface roughness was also improved by about 60 %. This study suggested that the tool wear and surface quality of high-hardness steel can be improved through the vibration cutting method in the machining of high hardness mold steel.

• 한국정밀공학회지
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• 제11권5호
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• pp.42-55
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• 1994

Presently, abrasive processing is on eof several methods for cutting and grinding brittle materials, and high quality in dimensional accuracy and surface roughness are often required as a structural components, therefore most of them has to be ground. In manufacturing of tungsten-carbide components, grinding by diamond wheel is usually adopted in order to provide configurational and dimensional accuracy to the components. The present study proposes the experi- mental research of optimum condition to the high quality surface grinding of the WC-Co material using diamond abrasive wheel in order to minimize the damage on the ground surface and to pursue the precise dimension by conventional grinding machine. Brief investigation is carried out to decrease the dressing is constant, theoretical grinding effect such as machining precision is changed according to the speed of workpiece. Accordingly, normal and tangential grinding forces, which are Fn, Ft were analyzed for the machining processes of WC-Co material to obtain optimum grinding conditions, 3-point bending test is carried out to check machining damage on the ground surface layer, which is one of sintered brittle materials.