• Journal of the Korean Society for Precision Engineering
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• v.17 no.7
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• pp.132-140
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• 2000

Plasma arc cutting is one of the most widely used processes in metal cutting fields and is a process that produces parted metal plates by cutting them with an arc plasma established between the electrode tip and the plate(workpiece). When the tip-to-workpiece distance varies during cutting, the cut quality, for example the kerf width, is deteriorated by the change of plasma arc. The variations of tip-to-workpiece distance are due to the different factors such as inaccuracies in setting the torch or workpiece, thermal distortions during cutting, and uneven surface of workpiece. The control to keep the tip-to-workpiece distance constant is thus indispensable to improve the flexibility of automatic plasma arc cutting system applications. In this study, an arc sensor which utilizes the electrical signal obtained from the plasma arc itself was developed. The arc sensor has an advantage that no particular sensing device is necessary and real-time sensing of the tip-to-workpiece distance is possible directly under the plasma arc. The relationship between plasma arc voltage and tip-to-workpiece distance was determined through the repeated experimental results. The model was used for developing an automatic tip-to-workpiece distance control system of plasma arc cutting. It could be shown that the proposed system has a successful capability of tip-to-workpiece distance control.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1799-1802
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• 2003

The commercial success of a new product is influenced by the time to market. Shorter product leadtimes are of importance in a competitive market. This can be achieved only if the product development process can be realized in a relatively small time period. New cutting inserts are developed by a time consuming trial and error process guided by empirical knowledge of the mechanical cutting process. The effect of previous cutting on chip formation and the surface residual stresses has been studied. The chip formation is not affected much. There is only a minor influence from the residual stress on the surface from tile first cutting on the second pass chip formation. Thus, it is deemed to be sufficient to simulate only the first pass. The influence of the cutting speed and feed on the residual stresses has been computed and verified by the experiments. It is shown that the state of residual stresses in the workpiece increases with the cutting speed. This paper presents experimental results which can be used for evaluating computational models to assure robust solutions. The general finite element code ABAQUS/Standard has been used in the simulations. A quasi-static simulation with adiabatic heating was performed. The path for separating the chip from the workpiece is predetermined. The agreement between measurements and calculation is good considering the simplifications introduced.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.10
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• pp.135-140
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• 1997

The detection of cutting tool states in machining is important for the automation. The information of cutting tool states in metal cutting process is uncertain. Hence a industry needs the system which can detect the cutting tool states in real time and control the feed motion. Cutting signal features must be sifted before the classification. In this paper the Fisher's linear discriminant function was applied to the pattern recognition of the cutting tool states successfully. Cutting conditions and cutting force para- meters have shown to be sensitive to tool states, so these cutting conditions and cutting force paramenters can be used as features for tool state detection.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.9
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• pp.2286-2293
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• 1993

The study presents the development of a cost-effective CAD/CAM system for metal moulds by use of personal computer. In the personal CAD/CAM system named DKSYS, metal moulds are defined by the operations of basic elements such as prism, pyramid and sphere, plane, rotational body, and surface elements including curved surface. The internal expression of shape elements in the computer is based on the wire model, which is a set of cross-sectional curves of the shape elements. With the addition of OMS system to CAD/CAM system the optimum cutting condition can be selected automatically. After programming NC information with the form definition and the optimum cutting condition, the metallic mould can be formed by transferring cutting information to CNC machine through DNC system. Using a computer for the above process, it is possible to increase the productivity and reduce the cost.

• Design & Manufacturing
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• v.16 no.3
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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.

• Transactions of Materials Processing
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• v.19 no.3
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• pp.191-196
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• 2010

Tungsten-carbide as typical difficult-to-cut material has excellent mechanical properties such as high thermal resistivity, mechanical strength and chemical durability. However, it is next to impossible for tungsten-carbide to be fabricated the needed parts by cutting process. In this study, for establishing the micro fabrication method of tungsten-carbide for micro injection or compression molding core, the investigation on micro cutting characteristics of tungsten-carbide green part which is made by powder injection molding process and easy to cut relatively was performed. For this, micro endmilling experiments of tungsten-carbide green part were performed according to various cutting conditions. Finally, the wear trend of micro endmill and the appearance of micro rib according to feed-rate and cutting depth per step were analyzed through SEM images of micro cutting feature and microscope images of micro tools.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.6
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• pp.84-91
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• 2003

In metal cutting operation, it is very important that predict cutting force and work surface. Vibration is an unstable cutting phenomenon which is due to the interaction of the dynamics of the chip removal process and the structural dynamics of machine tool. When vibration on, it reduces tool life, results in poor surface roughness and low productivity of the machining process. In this study, the experiments were conducted in machining center without cutting fluid to investigate the phenomenon of vibration. In the experiments, accelerometers were set up at the tail stock and tool holder and signals were picked up. Surface roughness profiles are generated under the ideal condition and the occurrence of vibration based on the surface shaping simulation model.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.184-189
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• 2003

In metal cutting operation, it is very important that predict cutting force and work surface. Vibration is an unstable cutting phenomenon which is due to the interaction of the dynamics of the chip removal process and the structural dynamics of machine tool. when Vibration occurs, it reduces tool life, results in poor surface roughness and low productivity of the machining process. In this study, the experiments were conducted in machining center without cutting fluid to investigated phenomenon of the Vibration. In the experiments, accelerometers were set up at the tail stock and tool holder and the signals were picked up. In this paper, surface roughness profiles will be generated under the ideal condition and the occurrence of the vibration based on the surface shaping simulation model.

• Steel and Composite Structures
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• v.19 no.6
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• pp.1467-1481
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• 2015

This paper presents a contribution to improving an analytical thermo-mechanical modeling of Oxley's machining theory of orthogonal metals cutting, which objective is the prediction of the cutting forces, the average stresses, temperatures and the geometric quantities in primary and secondary shear zones. These parameters will then be injected into the developed model of Karas et al. (2013) to predict temperature distributions at the tool-chip-workpiece interface. The amendment to Oxley's modified model is the reduction of the estimation of time-related variables cutting process such as cutting forces, temperatures in primary and secondary shear zones and geometric variables by the introduction the constitutive equation of Johnson-Cook model. The model-modified validation is performed by comparing some experimental results with the predictions for machining of 0.38% carbon steel.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.26 no.4
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• pp.402-409
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• 2017

Selection of optimal cutting conditions is important for improving productivity and implementing efficient process control in metal machining. In this study, improvement of cutting conditions in machining using end-mills is studied by using deep-layered neural networks, which comprise an input layer, output layer, and two hidden layers. System networks are designed with inputs as cutting conditions, and they output the cutting force. A pseudo-inverse network is designed that has the adjustable cutting condition as output and cutting force and other cutting conditions as input. The combination of the system network and pseudo-inverse network enables selection or improvement of cutting conditions that results in the expected cutting force.