• 한국기계가공학회지
• /
• 제18권6호
• /
• pp.26-32
• /
• 2019

Ball end mills used for high-speed and high-precision machining require longer machining time than flat end mills or face cutters, since the tool diameter is limited and the rigidity is reduced by the characteristics of the tool's cutting edge: at the top end of the tool, the cutting speed approaches zero and hardly removes any material. Because there is little material removal at the top end of the ball end mill, the outer cutting edge performs the majority of the work; this irregular cutting force deforms the tool and shortens its life. In this study, we attached an eddy-current sensor to a tool to measure the deformation from the cutting force and we used a tool dynamometer to measure the cutting force. We found that the change in cutting force is dependent on the change in feed rate during square-shaped processing and, as the feed rate is accelerated, the cutting force also increases. Higher cutting forces increase tool deformation.

• 한국기계가공학회지
• /
• 제11권5호
• /
• pp.142-147
• /
• 2012

Machining tool conditions directly affect to quality of product and productivity of manufacturing. Many researches performed for tool condition monitoring in machining process to improve quality and productivity. Conventional methods use characteristics of signal for cutting force, motor current consumption, vibration of machine tools and machining sound. Recently, diameter of machining tool is become smaller for minimizing of mechanical parts. Tool condition monitoring using conventional methods are relatively difficult because micro machining using small diameter tool has low machining load and high cutting speed. These days, the direct monitoring for tool conditions using vision system is performed actively. But, vision system is affected by external conditions such as back ground of image and illumination. In this study, minimizing technology of external conditions using distribution analysis of image data are developed in micro machining using small diameter drill and tap. The image data is gathered from vision system. Several sets of experiment results are performed to verify the characteristics of the proposed machining technology.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 1998년도 추계학술대회 논문집
• /
• pp.176-179
• /
• 1998

In general, machining time by electrical discharge machining (EDM) process is much longer than that of cutting process, so rough-cut has done for the purpose of reducing machining time prior to EDM Nowadays EDM speed is improving due to the advance of EDM capacity. Therefore a new method, machining a raw material directly by EDM without rough-cut, is used widely. EDM area is varies according to the EDM position in three-dimensional EDM process, so EDM parameters should be determined adaptively based on the EDM area to increase productivity. However it is difficult to calculate EDM area corresponding to the EDM position the EDM workers who have experience in shop floor determine machining parameters by experience. This paper proposes a method for determining EDM parameters based on EDM area corresponding to EDM position.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 2002년도 추계학술대회 논문집
• /
• pp.123-128
• /
• 2002

The machining parameters for the wire electrical discharge machining(WEDM), including no load voltage, pulse-on time, pulse-off time, wire tension, water flow rata offset etc. should be chosen properly so that a better performance can be obtained An optimum selection of machining parameters relies heavily on the operators technologies and experience. This study presents a method by means of Taguchi method to select optimal machining parameter combination for an cutting speed or surface roughness. Experimental results demonstrate that the machining models are appropriate and the derived machining parameters satisfy the real requirements in notice.

• 소성∙가공
• /
• 제13권3호
• /
• pp.262-267
• /
• 2004

Ultrasonic machining has been known as one of the conventional machining methods in the glass fabrication processes. In ultrasonic machining, typically, glass is removed by the impulse energy of the abrasive generated by the ultrasonic power. However, when the machining feature decrease under hundreds of micrometers, as conventional ultrasonic machining uses only the impulse energy of the abrasive, the speed of ultrasonic machining decreases significantly and the surface roughness becomes deteriorated. To overcome this size effect, the chemicals which can erode glasses, such as HF, XF, etc, are added to the slurry. The chemical-assisted ultrasonic machining method, so called, is another alternating effective way for micro machining of glasses. In previous work, we used the hydrofluoric acid (HF) as an additive chemical. But, as the HF solution is too poisonous to be used as a ultrasonic process additive, it is needed to be substituted by other safe chemicals. As results of the machinability comparison of several chemicals, the GST-500F was selected to replace the HF. The GST-500F (pH $4.0{\pm}1.0$) is non-volatile, odorless. During experimental works, it was shown that the machining rate increases 1.5 times faster than the conventional ultrasonic machining. The machining load also decreases. However, the enlargement of the hole diameter and significant tool wear are still the problems to be solved.

• 한국공작기계학회논문집
• /
• 제16권1호
• /
• pp.40-46
• /
• 2007

High speed machining has become the main issue of metal cutting. Due to increase of the rotational speed of the spindle, problems such as the run-out errors and reduced stiffness must be overcome to improve the machining accuracy. In order to solve the problems, it is important to determine the appropriate clamping unit and tooling system. This paper presents an investigation into an analysis of static stiffness in the main spindle interface. Finite element analysis is performed by using a commercial code ANSYS according to variation of cutting force, clamping force and rotational speed. From the finite element results, it is shown that the rotational speed and clamping force mostly influence on the variation of the static stiffness in the main spindle interface.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 2000년도 춘계학술대회논문집 - 한국공작기계학회
• /
• pp.332-338
• /
• 2000

The high speed machining is now one of the most effective manufacturing methods to achive higher productivity. However, due to the increased cutting temperatures caused by increased cutting speed, tool wear become larger. Especially in high speed face milling, cutting tools are exposed not only to high cutting temperatures, but also to mechanical and thermal shock stresses. It is essential, therefore, to know the wear characteristics of tool materials in high speed machining. This study presents an experimental investigation of the cutting performance of CBN tools in high speed face milling of gray cast iron FC25. The effect of cutting conditions and cutting length on flank wear of CBN tools and roughness of machined surfaces is investigated. The cutting parameters involved were ; cutting speeds in the range of 600to 1800 m/min, feed of 0.1 mm/tooth, and depth of cut of 0.3mm.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 1996년도 추계학술대회 논문집
• /
• pp.95-99
• /
• 1996

The form accuracy of parts has become an important parameter. Therefore dimensional tolerance and geometric tolerance are used in design to satisfy required quility and functions of parts. But the informations for machining conditions, which can satisfy the assigned geometric tolerance in design, are insufficient. The objectives of this research are to study the effects of the grinding parameters such as traverse speed, work speed, depth of cut, and dwell time on the after-ground workpiece shape, and to find out the major parameters among these parameters. Finally, a methodology is proposed for getting the optimal grinding condition for precision workpiece The results are as follows; The effects of work speed and depth of cut on workpiece shape are ignorable compared to the effect of traverse speed. These is the optimal dwell time depending on the traverse speed. The optimal dwell time is decreasing when the traverse speed is increased.

• 한국공작기계학회논문집
• /
• 제14권2호
• /
• pp.21-26
• /
• 2005

From on the machining center cutting work of 5534, the characteristics such as spindle speed and feed speed fir the third point height, average spacing of roughness peaks, bearing ratio, center line average, ten point height. experiments is roughness for sampling length determine to measuring length of cutting feed speed 200, 400, 600, 800mm/min and spindle speed 800, 1000, 1200, 1400rpm. Third point height is spindle speed with most suitable cutting condition 1000rpm. Third point height is feed speed with most suitable cutting condition 400mm/min. Average spacing of roughness peaks are spindle speed with most suitable cutting condition feed speed increased to average spacing of roughness Peaks are increased. Spindle speed increased to average spacing of roughness peaks are decreased. Bearing ratio is spindle speed with feed speed increased to bearing ratio decreased. Center line average is spindle speed with most suitable cutting condition at 1200rpm feed speed with most suitable cutting condition at 200mm/min to cutting foe roughness suddenly decreased. Ten point height is spindle speed with most suitable cutting condition 1200rpm at ten point height cutting face roughness to decreased and feed speed with most suitable cutting condition 800mm/min at ten point height cutting face roughness to decreased.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2003년도 춘계학술대회 논문집
• /
• pp.589-592
• /
• 2003

In the machining process of micros shape by using high-precision machining system and micro end-mill, it is important for machining characters of tools to be grasped in order to stably use tools of micro end-mill. In this study. we carried out an analytical experiment of basic machining features by using end-mill tools for the purpose of damage prevention and manufacture of high quality when the tools of micro end-mill are used. This experiment used a micro machining system with high precision and a variety of end-mill tools commercialized from tens to hundreds microns in diameter. To establish an optimal machining condition without tool damage, cutting force was analyzed according to the changes of tool diameter and cutting conditions such as cutting speed. feed rate, depth of cut. And an examination was performed for the shape and surface illumination of machining surface according to the changes of machining conditions. Based on these micro machining conditions, micro square pillar, cylinder shaft. thin wall with high aspect ratio, and micro 3-D structures such as micro gear and fan were manufactured.