• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.973-976
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• 1997

Process behavior in metal cutting results from the chip formation process which is not easily observable and measurable during machining. By means of the finite element method chip formation in orthogonal metal cutting is modeled. The reciprocal interaction between mechanical and thermal loads is taken into consideration by involving the thermo-viscoplastic flow behavior of workpiece material. Local and temporal distributions of stress and temperature in the cutting zone are calculated depending on the cutting parameters. The calculated cutting forces and temperatures are compared with the experimental results obtarned from orthogonal cutting of steel AISl 4140. The model can be applied in process design for selection of appropriate tool-workpiece combination and optimum cutting conditions in term of mechanical and thermal loads.

• Journal of the Korean Society for Precision Engineering
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• v.7 no.2
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• pp.85-94
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• 1990

In automatic metal cuttings, the chip control is one of the serious problems. So the automatic detection of chip forms is essential to the chip control in automatic metal cuttings. Cutting experiments were carried out under the variety of cutting conditions (cutting speed, feed, depth of cut and tool geometry) and with workpiece made of steel (S45C), and cutting forces were measured in-processing by using a piezoelectric type Tool Dynamometer. In this report, the frequency analysis of dynamic components, the upper frequency distributions, the ratio of RMS values, the numbers of null point and the probability density were calculated from the dynamic componeents of cutting forces filtered through various band pass filters. Experimental results showed that computer chip form monitoring system based on the cutting forces was designed and simulated and that 6 type of chip forms could be detected while in-process machining.

• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.1-13
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• 2016

The increase of consumer needs for quality metal cutting related products with more precise tolerances and better product surface roughness has driven the metal cutting industry to continuously improve quality control of metal cutting processes. In this paper, two different approaches are discussed. First, design of experiments (DOE) is used to determine the significant factors and then fuzzy logic approach is presented for the prediction of surface roughness. The data used for the training and checking the fuzzy logic performance is derived from the experiments conducted on a CNC milling machine. In order to obtain better surface roughness, the proper sets of cutting parameters are determined before the process takes place. The factors considered for DOE in the experiment were the depth of cut, feed rate per tooth, cutting speed, tool nose radius, the use of cutting fluid and the three components of the cutting force. Finally the significant factors were used as input factors for fuzzy logic mechanism and surface roughness is predicted with empirical formula developed. Test results show good agreement between the actual process output and the predicted surface roughness.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.1
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• pp.121-133
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• 2020

Underwater cutting has a different mechanism than dry cutting, and there are more restrictions than benefits. Due to these constraints, research and development of underwater cutting has been very limited. At present, reactor dismantling is emerging as an important task worldwide, and reactor pressure containers, a key part of the reactor, are decommissioned based on underwater cutting. Reactor pressure containers are high-level radioactive waste, which is one of the main goals of today, such as to bridge the gap between environmental, safety, and cutting performance; hence, a process suitable for cutting should be applied. Therefore, many studies are being conducted on underwater cutting in connection with the dismantling of nuclear reactors in various areas in order to find appropriate processes. This paper first introduces the core technology of underwater cutting processes and discusses various processes. The emphasis is then placed on the adequacy of the reactor dismantling application. More specifically, we examine the suitability for the mechanical and thermal cutting processes, respectively, to find a solution suitable for dismantling a reactor. We discuss how each solution can sufficiently perform the specified functions at each stage of reactor dismantling and suggest that these processes can perform all of the work of underwater cutting.

• Transactions of Materials Processing
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• v.12 no.4
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• pp.358-363
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• 2003

Adiabatic shear bands have been observed in the serrated chip during high strain rate metal cutting process of medium carbon steel and titanium alloy The recent microscopic observations have shown that dynamic recrystallization occurs in the narrow adiabatic shear bands. However the conventional flow stress models such as the Zerilli-Armstrong model and the Johnson-Cook model, in general, do not predict the occurrence of dynamic recrystallization (DRX) in the shear bands and the thermal softening effects accompanied by DRX. In the present study, a strain hardening and thermal softening model is proposed to predict the adiabatic shear localized chip formation. The finite element analysis (FEA) with this proposed flow stress model shows that the temperature of the shear band during cutting process rises above 0.5Τ$_{m}$. The simulation shows that temperature rises to initiate dynamic recrystallization, dynamic recrystallization lowers the flow stress, and that adiabatic shear localized band and the serrated chip are formed. FEA is also used to predict and compare chip formations of two flow stress models in orthogonal metal cutting with AISI 1045. The predictions of the FEA agreed well with the experimental measurements.s.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.2
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• pp.161-170
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• 2001

Synthetic water-based metal-cutting fluids are increasingly popular in the metal-working industry because of its environmental friendliness. The propose of this study is to investigate the synergistic effect of combining polyethylene glycol and common fatty acid in formulating a metal-cutting fluid. The tested metals were aluminum, copper and steel, and the test was performed with a modified drilling machine. From the study, it was found that there existed some synergistic effects on the drilling efficiency of the metals to decrease of cutting time, cutting energy, torque as well as the smoothness of surface depended on the formulation ratio of the two fluids.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.6
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• pp.114-120
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• 2001

It is necessary to develop a new metal cutting technology which does not use cutting fluid, since cutting fluid can have undesirable effect on workers's health and working environment. For this to be possible, it is necessary to replace the conventional method of using cutting fluid, whose basic functions are removing chip and heat, and providing lubrication between tool and chip. In this work, cooled air is utilized in order to replace cutting fluid. Experiments were carried out while cutting workpiece with HSS flat endmill under a variety of supply conditions for cooled air. Also the performance characteristics of the air cooling system. which was built for the experiments, were carefully analyzed. For the reliable operation of air cooling system. moisture contained in the cooled air had to be removed before being supplied to the workpiece and tools. It was found that depending on the amount of its flow rate the temperature of cooled air changes at the time of injection from the nozzle. The flow rate of cooled air also plays an important role in removing the accumulated chip on the workpiece. After comparing the flank wear for the three cases of using cooled air, cutting fluid, and pure dry technique, it was demonstrated that the level of flank wear was similar for the cases of cooled air and cutting fluid. The pure dry technique, however, showed higher level of flank wear than cooled air.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1998.10a
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• pp.158-163
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• 1998

In this paper, the cutting characteristics and cutting mechanism of polystyrene foam was experimentally investigated. It was found that polystyrene foam has different cutting characteristics and cutting mechanism comparing with that of normal metal materials. By using the experimental results, the optimal cutting tool was designed and examined for approving the cuttingability of polystyrene foam.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.6
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• pp.906-915
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• 1986

This study reviewed the theory of acoustic emission applying generation of acoustic emission in metal cutting and proposed a relationship between fundamental cutting parameters and the root mean square (RMS) voltage of the acoustic emission on the basis of the mechanics of the orthogonal cutting operation. Experimental results are presented for 6063-T5 Auminum and the validity of this relationship is evaluated by a series of tests varying cutting speed, feed rate and rake angle in orthogonal cutting. The original formula derived theoretically has been modified in order to utilize independent of fundamental cutting parameters. RMS voltage of acoustic emission depends on cutting speed and strain rate, but it is not much affected by feed rate. Applying lubricant, the drop of RMS level has been observed.

• Journal of the Korean Society of Industry Convergence
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• v.16 no.3
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• pp.95-102
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• 2013

It is indispensable to modern society metal processing since the industrialized rapidly, but it is a metalworking cutting fluid immediately. In addition, this means selecting a emulsion on the basis of quality criteria processing method, the material of the material, cutting depth, cutting speed, Djourou fence Liang, and surface roughness, cutting oil, the shape of the device based on the emulsion, I will be the structure of the tank, filtration equipment also changes. In particular, acting bacteria is now breeding in response to the passage of time due to metal ion degradation due to heat generated hydraulic fluid leakage, humidity tung, during processing, seep from processing material at the time of processing the water-soluble cutting oil for generating the malodor by dropping significantly the performance of the cutting oil to corruption from, sometimes by introducing various additives to suppress spoilage in advance. In this study, we expect the effect of the cost reduction in the extension of fluid replacement cycle through the application of the management apparatus and deep understanding in the management of cutting fluid, the working environment through the understanding and interest of workers in the production site more than anything I try to become useful for the improvement.