• Clean Technology
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• v.12 no.3
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• pp.182-189
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• 2006

In this study, high speed machining is evaluated with regard to economical and environmental effects. Considering environmental loads, machining costs are analyzed with the mathematical models of machining economics and cutting fluid loss. Data from the tool life experiments of high speed milling and turning are used for the analysis. The analysis of high speed milling shows that the machining cost decreases as increasing the cutting speed. In turning process, the cooling method using cutting fluid shows the minimum machining cost. Considering both machining and environmental costs, cooling method using cold air is superior to other methods.

• 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.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.2
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• pp.380-384
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• 1993

In precision wire electrode discharge machining by CAD/CAM, it is the most important problem on machining method to determine the wire electrode offset amout from the accurate calculation of discharge gap in order to increase the machining accuracy, after fixing the main machining conditions such as machining speed, wire tension, coolant conductivity, gap vlotage. The present study shows the relationships between discharge gap and main machining conditions by means of a series of experiment concerned with the gap using the workpiece of STD 11, and suggests the experimental eguation to calculate the accurate wire electrode offset amount under the given machining conditions for spot workers.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.1858-1863
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• 2003

The properties of a machine tool greatly affect machining quality since a machine tool has large variance in its features. Machine tool makers want to find best machining condition with the one that they have built. Machine builders need to develop test specimen since it helps finding characteristics of machine tools when the machining properties of the specimen are analyzed. This paper develops test specimen to identify features of the main spindle, the feeding device, and the frame of a machine tool. The specimen is machined with a high speed machine and the features of the machine are analyzed with test items. They are surface roughness, overshoot in axial movement, errors in circular movement, feeding with small movement, and compensational error. This work can improve usability for a machine tool in machining practice.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.38-47
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• 2002

Machining quality has been improved with the development of cutting tools. However, it is difficult to obtain a high degree of quality in machining a deep pocket with a long end mill, since machining accuracy is mainly dependent on the stiffness of the cutting tool and tool holder. To improve machining quality in machining a deep pocket using an end mill, the performance by cutting condition compare with others. Owing to this problem, it is necessary to select suitable tool and holder in the deep pocket machining. In this study, the hydraulic holder for the high speed machining is introduced and the performance of that is compared with others according to cutting conditions. The cutting parameters involved were; slenderness ratio in the range of 3 to 6 (L/D), radial depth of cut from 0.01 to 0.05 mm. Cutting force and surface roughness, precision of form were observed during the experiment to investigate cutting state.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.7
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• pp.94-100
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• 1999

This study adopted the ultra precision machining system which was composed of an air bearing spindle, a granite bed, air pad and a linear feeding mechanism. It also applied the cutting experiment on the aluminum alloy. To evaluate the safety of high speed machining, we examined the surface roughness according to the changes of cutting speed and obtained the speed limit. This paper also studied the effect of cutting condition such as feed rates and depths of cut on the surface roughness within the speed limit. This provided practical information regarding ultra precision machining.

• International Journal of Precision Engineering and Manufacturing
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• v.3 no.4
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• pp.31-36
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• 2002

A continuous tool-path, that is to cut continuously with the minimum number of cutter retractions during the cutting operations, is developed in order to minimise the fluctuation of cutting load and the possibility of chipping on the cutting edge in HSM (high-speed machining). This algorithm begins with the offset procedure along the boundary curve of the sculptured surface being machined. In the of offset procedure, the offset distance is determined such that the scallop height maintains a constant roughness to ensure higher levels of efficiency and quality in high-speed machining. Then, the continuous path is generated as a kind of the diagonal curve between the offset curves. This path strategy is able to connect to neighbor paths without cutter retractions. Therefore, the minimum tool retraction tool-path can be generated And, it allows the sculptured surface incorporating both steep and flat areas to be high-speed machined.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.500-503
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• 2003

The tool geometry parameters and cutting process have complex relationships. Until now, various cutting test were needed to acquire optimal design of end mill for the purpose of high speed machining, due to the insufficient knowledge about cutting process in high speed machining. Using various tools with different geometry, relationships between tool geometry parameter (rake angle, clearance angle, length of cutter) and cutting process (cutting force, surface accuracy, surface roughness) have been studied. Acquired data can be used to design optimal tool for high speed machining

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.422-427
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• 2004

The tool geometry parameters and cutting process have complex relationships. Until now, various cutting test were needed to acquire optimal design of end mill for the purpose of high speed machining, due to the insufficient knowledge about cutting process in high speed machining. Using various tools with different geometry, relationships between tool geometry parameter (rake angle, clearance angle, length of cutter) and cutting process (cutting force, surface accuracy, surface roughness) have been studied. Acquired data can be used to design optimal tool for high speed machining and to develop a software for design of end mill geometry.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.1
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• pp.22-27
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• 2004

Recently, environmental pollution has become a significant problem in industry and many researchers have investigated in order to preserve the environment. Environmentally conscious machining and technology have more important position in machining process, because cutting fluid has bad influence on the environment in milling process. This research is the experimental study on high speed machining of aluminum alloys through environmentally conscious machining. In this study, the surface roughness and chip appearance was investigated in the machining of aluminum alloys by dry machining, using cutting fluid and oil mist.