• KSTLE International Journal
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• 제3권2호
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• pp.95-100
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• 2002

Electrochemical discharge machining is a very recent technique for non-conducting materials such as ceramics and glasses. ECDM is conducted in the NaOH solution and the cathode electrode is separated from the solution by H$_2$ gas bubble. Then the discharge is appeared and the non-conductive material is removed by spark and some chemical reactions. In the ECDM technology, the H$_2$ bubble control is the most important factor to stabilize the discharging condition. In this paper we proposed the discharge peak monitoring/discharging duty feedback algorithms fur the discharge stabilization and the feasibility of this algorithm is verified by various pattern machining in the constant preload conditions for the cathode electrode.

• 대한기계학회논문집A
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• 제27권3호
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• pp.357-362
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• 2003

Recently, the demand for advanced technology of high precision and high efficiency processing of hard materials such as inconel is increasing with progress of industrial goods. However, the machinability of inconel is very inferior to the other conventional industrial materials and the machining technology for inconel involves many problems to be solved in machining accuracy, machining efficiency, etc. Therefore it is needs to establish the machining technology. The purpose of this study is to develop an advanced ultrasonic vibration machining technology for inconel, using the 60KHz and 75KHz high frequency, amplitude about 8${\mu}{\textrm}{m}$ and 4${\mu}{\textrm}{m}$, respectively. As the result, this new ultrasonic vibration machining is reasonable and suitable for the high efficient. accuracy machining method of inconel.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2003년도 춘계학술대회 논문집
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• pp.167-172
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• 2003

The machining method by using end-milling tool has been applying in machining structures of various shapes because of the availability. Recently, all kinds of industries based on the parts of micro shape are developing, and the demands of mechanical micro machining technology are Increasing suddenly to produce these parts. According to such changes, the technology of the micro end-milling machining is applying as one of the most important machining means. This research is to aim at developing machining technology for various micro structures using micro end-mill. This paper introduces micro mechanical machining system with ultra precision, and demonstrates methods manufacturing all sorts of parts and moldings for industry and examples of applicable machining by using micro end-milling tool of micro sizes from hundreds to tens in diameter.

• International Journal of Precision Engineering and Manufacturing
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• 제6권4호
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• pp.44-48
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• 2005

As mechanical components are miniaturized, the demands on micro die/mold are increasing. Micro mechanical components usually have high hardness and good conductivity. Micro electrical discharge machining (MEDM) can thus be an effective way to machine those components. In micro cavity fabrication using MEDM, it is observed that the bottom surface of the cavity is distorted. Electric charges tend to be concentrated at the sharp edge, and debris cannot be drawn off easily at the center of the bottom surface. These two phenomena make the bottom surface of electrode and workpiece distort. As machining depth increases, the distorted shape of the electrode approaches hemisphere. This process is affected by both capacitance and the size of electrode. By using a smaller electrode than the desired cavity size and appropriate tool movement, bottom shape distortion can be prevented.

• Journal of Welding and Joining
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• 제29권2호
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• pp.56-63
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• 2011

his paper aimed to understand the residual stress in the dissimilar metal welds of nuclear power plant. Two kinds of residual stress were considered, which caused by welding and machining. Residual stress due to mechanical machining was measured by hole-drilling technique and x-ray diffraction method for the SA508 and F316L. Weld residual stress at dissimilar metal weld between SA508 and F316L was evaluated by FEA. Residual stress profiles were obtained for the inside surface and through thickness of welds. Machining effect was also analyzed by FEA. According to the residual stress measurement, it was observed that mechanical machining can generate tensile stress on the surface of the test material. However, FEA results showed that mechanical machining did not increase the tensile stress on the surface of weld region. Further study with more elaborate measurement and numerical analysis is required to identify the effect of machining on residual stress in the dissimilar metal weld region.

• Journal of Electrochemical Science and Technology
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• 제10권3호
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• pp.276-283
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• 2019

Nitinol is an alloy of nickel and titanium. Nitinol is one of the shape memory alloys(SMA) that are restored to a remembered form, changing the crystal structure at a given temperature. Because of these unique features, it is used in medical devices, high precision sensors, and aerospace industries. However, the conventional method of mechanical machining for nitinol has problems of thermal and residual stress after processing. Therefore, the electrochemical machining(ECM), which does not produce residual stress and thermal deformation, has emerged as an alternative processing technique. In addition, to replace the existing experimental planning methods, this study used deep neural network(DNN), which is the basis for AI. This method was shown to be more useful than conventional method of design of experiments(RSM, Taguchi, Regression) by applying deep neural network(DNN) to electrochemical machining(ECM) and comparing root mean square errors(RMSE). Comparison with actual experimental values has shown that DNN is a more useful method than conventional method. (DOE - RSM, Taguchi, Regression). The result of the machining was accurately and efficiently predicted by applying electrochemical machining(ECM) and deep neural network(DNN) to the shape memory alloy(SMA), which is a hard-mechinability material.

• 한국정밀공학회지
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• 제25권10호
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• pp.41-47
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• 2008

This study aims to obtain machining characteristics during AFM (Atomic force Microscope) machining of silicon wafers and to monitor the machining states using acoustic emission. As in micro scale machining, two distinct regimes of deformation, i. e. ploughing regime and cutting regime were observed. First, the transition between the two regimes are investigated by analyzing the "pile-up" during machining. As far as in process monitoring is concerned, in the ploughing repime, no chips have been formed and related AE RMS values are relatively low, In the mean time, in the cutting regime, the RMS values are significantly higher than the ploughing regime, with apparent chip formation. From the results, we found out that the proposed scheme can be used for the monitoring of nanomachining, especially for the characterization of nanocutting mode transition.

• Journal of Mechanical Science and Technology
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• 제20권2호
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• pp.227-233
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• 2006

Engineering ceramics have many unique characteristics both in mechanical and physical properties such as high temperature hardness, high thermal, chemical and electrical resistance. However, its machinability is very poor in conventional machining due to its high hardness and severe tool wear. In the current experimental study, alumina $(Al_2O_3)$ was ultrasonically machined using SiC abrasives under various machining conditions to investigate the material removal rate and surface quality of the machined samples. Under the applied amplitude of 0.02mm, 27kHz frequency, three slurry ratios of 1:1, 1:3 and 1:5 with different tool shapes and applied static pressure levels, the machining was conducted. Using the mesh number of 240 abrasive, slurry ratio of 1:1 and static pressure of $2.5kg/cm^2$, maximum material removal rate of $18.97mm^3/min$ was achieved. With mesh number of 600 SiC abrasives and static pressure of $3.0kg/cm^2$, best surface roughness of $0.76{\mu}m$ Ra was obtained.

• International Journal of Precision Engineering and Manufacturing
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• 제9권2호
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• pp.11-17
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• 2008

Critical erosion kinetic energy models for radial/median cracks and lateral cracks in a workpiece are established in this study. We used experimental results to demonstrate that the fracture erosion resistance and erosion machining number could be used to evaluate the brittle fracture resistance and machinability of a workpiece. Erosion kinetic energy models were developed to predict brittle fracture and ductile shear, and a critical erosion kinetic energy model was developed to predict the transition from brittle fracture to ductile shear. These models were verified experimentally.

• 한국정밀공학회지
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• 제19권7호
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• pp.133-140
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• 2002

Ultrasonic Machining (USM) is widely used in cutting of non-conductive, brittle workpiece materials such as engineering ceramics. However, USM has a limitation in its application to micro machining because problems are occurred in attaching micro tools to the machine and maintaining high precision. Therefore Micro Ultrasonic Machining (MUSM) with WEDM is proposed in this research. The experiments are produced as the change of shaft diameter and abrasive size.