• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.1003-1007
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• 2002

Micro-EDM is generally used far machining micro 3-D structure. For micro-EDM, first of all, micro-electrode fabrication is needed and WEDG system is proposed for tool electrode fabrication method. When tool electrode is fabricated using WEDG system, its characteristics are under the control of many EDM parameters. Also relations between the parameters affect electrode fabrication. In this study, experiments are carried out to analyze effects of EDM parameters on micro-electrode fabrication. Experimental method and analysis are used to experimental design method. Factors used in experiments are composed of applied voltage, capacitance, wire feed rate, spindle rotating speed, machining time. As a result of experiments, wire feed rate, machining time and capacitance is proportional to gap distance(material removal), the other parameters(applied voltage, spindle rotating speed) and relations between the parameters have little influence on machining.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.59-64
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• 2002

Recently the applications of high speed machining are increasing due to the need for high performance and high accuracy machining and machining for difficult-to-cut material. However, the high speed machining also accompanies some problems: the product quality can be degraded due to the tool wear and the product cast can go up due to frequent tool replacements. Therefore, it is necessary to develop a technique of quantitative tool wear measurement to determine the precise timing for tool replacement. In this respect, this study suggests a reliable technique far the reduction of error components by developing a system using a CCD camera and an exclusive jig to be able to precisely measure the size of tool wear in flat end mill for high speed machining.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.551-554
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• 2002

The paper discusses new approach for machining operation simulation using enhanced Z map algorithm. To extract the required geometric information from NC code, suggested algorithm uses supersampling method to enhance the efficiency of a simulation process. By executing redundant Boolean operations in a grid cell and averaging down calculated data, presented algorithm can accurately represent material removal volume though tool swept volume is negligibly small. Supersampling method is the most common form of antialiasing and usually used with polygon mesh rendering in computer graphics. The key advantage of enhanced Z map model is that the data structure is same with conventional Z map model, though it can acquire higher accuracy and reliability with same or lower computation time. By simulating machining operation efficiently, this system can be used to improve the reliability and efficiency of NC machining process as well as the quality of the final product.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.129-134
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• 2000

This paper presents the development of ultra-precision machining process of large aspheric aluminum mirrors with a maximum diameter of 620 mm. An ultra-precision machine, "Nanoturn60", developed by Daewoo Heavy Industries Ltd. is used for machining and motion errors of the machine are compensated by using the FTS developed by IAE(Institue for Advanced Engineering) during the machining process. To check the form accuracy of machined aspheric surfaces, on-machine form measurement system is developed. This measurement system consists of air bearing touch probe, straight edge, and laser sensor. With in-process error compensation by FTS(Fast Tool Servo), aspheric mirrors with the from accuracy of submicron order are obtained. obtained.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.743-747
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• 1997

Polishing work for a curved surface die demands simple and repetitive operations and requires much time while it also demands high precision. Therefore it is operated by skilled worker in handiwork. Howener workers avoid polishing work gradually because of the poor environments such as dust and noise. In order to reduce the polishing time and to alleviate the problem of shortage of skilled workers, researches for automation of polishing have been pursued in the developed countries. In the research, a polishing robot with 2 degrees of freedom motion attached to machining center with 3 degrees of freedom and pneumatic system forms an automatic polishing system which keeps the polishing tool vertically on the surface of die and maintains constant pneumatic pressure. A synchronization between machining center and polishing robot is accomplished by using M code of machining center. A rulled surface and shadow mask are polished by the developed polishing robot.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.3
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• pp.315-322
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• 2011

High-accuracy micropatterns such as V-shaped microgrooves are increasingly in demand for various engineering areas. And the technical trend goes for large surface areas in precision machining technology. So micropatterns with large surface areas are expected to play an increasingly important role in today's manufacturing technology In this study, we focused on developing machining technologies. First, a machine vision system for precise tool setting is developed. Second, an on-machine measurement (OMM) system for large-area measurement is implemented. And also software for tool path generation and simulation is developed. With these technologies we fabricated large-surface micropatterns in an electroless nickel-plated workpiece with single-crystal diamond tools and a 32-in, $675mm{\times}450mm$ mold with tens of V-and pyramid-shaped micropatterns.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.326-333
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• 2004

This paper presents the structural characteristics analysis of a high-speed horizontal machining center with spindle speed of 50, 000rpm and feedrate of 120m/min. The spindle system is designed based on the built-in motor, angular contact ceramic ball bearings, oil-air lubrication and oil-jacket cooling method. The X-axis and Y-axis feeding systems are composed of the linear motor and linear motion guides, and the Z-axis feeding system is composed of the servo-motor, ball screw and linear motion guide. The structural analysis model of the high-speed horizontal machining center is constructed by the finite element method, and the validity of structural design is estimated based on the structural deformation of the high-speed horizontal machining center and spindle nose caused by the gravity and inertia forces.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.10
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• pp.172-179
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• 1998

To quickly determine the effect of the substitute component on the machine's performance is very important in the design and manufacturing processes. And minimizing machine cost and maximizing machine quality mandate predictability of machine accuracy. In this study, in order to evaluate the effects of the component's geometric errors and dimensions on the machining accuracy of gantry-type 5-axis machining centers, a geometric error analysis and virtual manufacturing system are developed based on the mathematical model for the shape generation motion of machine tool considering the component's geometric errors and dimensions, the solid modeling techniques and so on.

• Journal of the korean Society of Automotive Engineers
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• v.12 no.2
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• pp.59-70
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• 1990

Crack of breaking toughness of most Ceramics material is 1-5MPa .root.m but that of Zirconia Ceramics is improved to be 6-8MPa .root.m and its development of machining difficult-to-machine material is on the rise as urgent subject. For general Zirconia Ceramics machining, diamond grinding wheel is generally used by selecting an appropriate one and establishing grinding condition but due to such limitations as economics, grinding efficiency and machining geometry, great interest in machining method being used for diamond tool is emphasized. But it is reported that diamond tool is oxidized by cutting heat in the air and is graphitized in vacuum, which causes bad effects on tool life. In this study, to restraint cutting heat the internal side of tool is cooled, and restraint low temperature cooling system and being experimented. Further, the machinability of diamond tool for Zirconia Ceramics machining is analyzed with respect to tool wear and stress.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.3
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• pp.114-121
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• 1997

In this paper, the automated initial process planning for 3-axis NC machining of sculptured surfaces is persented. The solution algorithms determining three process planning functions, i.e. machining feasibility, setup orientation and feasible machine selection are developed. The machining feasibility is determined by means of BSM(Binary Spherical Map) which derives its solution quickly in algebraic form, and the setup orientation is determined so that the cutting force is minimized. Finally, the feasible machine is determined by computing the minimum motion ranges of each control axisl. The developed algorithms are tested by numerical simulations, convincing they can by readily implemented on the CAD/CAM system as a process planner.