• Korean Journal of Metals and Materials
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• v.46 no.6
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• pp.390-401
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• 2008

The objective of this study is to evaluate various machining characteristics of AlN-hBN machinable ceramics in micro end-milling process for its further application. First, AlN based machinable ceramics with hBN contents in the range of 10 to 20vol% were prepared by hot-pressing. Material properties of the composites, such as relative density, Vickers hardness, flexural strength, Young's modulus and fracture toughness were measured and compared. Then, micro end-milling experiments were performed to fabricate micro channels using prepared system. During the process, cutting forces, vibrations and AE signals were measured and analyzed using applied sensor system. Machined micro channel shapes and surface roughness were measured using 3D non-contact type surface profiler. From the experimental results, it can be observed that the cutting forces, vibrations and AE signal amplitudes decreased with increasing hBN contents. Also, measured surface roughness and profiles were improved with increasing hBN contents. As a result of this study, optimum machining conditions can be determined to fabricate desired products with AlN-hBN machinable ceramics based on the experimental results of this research.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.173-178
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• 2003

Recently, according to the development of mechatronics industry that was composed of NT, ST, IT, RT and etc, the 1 necessity of nano-parts was increased. Because of the necessity, this research was started for improving work precision of the parts as fixing UPCU( Ultra Precision Cutting Unit)on lathe. So, in this research we executed the modeling of UPCU (Ultra Precision Cutting Unit) by the application of PZT, the relationship between the displacement of tool in UPCU and the cutting force of it has been in take a triangular position in the case of plane cutting. The modeling of system that is containing the fine displacement was performed. Also, we found like to find the optimal cutting condition through the simulation of relationship between the displacement and the cutting force.

• Design & Manufacturing
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• v.17 no.4
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• pp.1-7
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• 2023

In the fabrication of curved multi-display glass for automotive use, the surface roughness of the mold is a critical quality factor. However, the difficulty in detecting micro-cutting signals in a micro-machining environment and the absence of a standardized model for predicting micro-cutting forces make it challenging to intuitively infer the correlation between cutting variables and actual surface roughness under machining conditions. Consequently, current practices heavily rely on machining condition optimization through the utilization of cutting models and experimental research for force prediction. To overcome these limitations, this study employs a surface roughness prediction formula instead of a cutting force prediction model and converts the surface roughness prediction formula into experimental data. Additionally, to account for changes in surface roughness during machining runtime, the theory of position variables has been introduced. By leveraging artificial neural network technology, the accuracy of the surface roughness prediction formula model has improved by 98%. Through the application of artificial neural network technology, the surface roughness prediction formula model, with enhanced accuracy, is anticipated to reliably perform the derivation of optimal machining conditions and the prediction of surface roughness in various machining environments at the analytical stage.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.12
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• pp.171-178
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• 2002

With increasing the needs for micro and precision parts, micro machining technology using micro tools has been studied to fabricate a small part with high density such as electronics, optics, communications, and medicine industry more than before. Though these micro tools have developed rapidly, it is difficult to apply them to micro fabrication technologies, because of the inherent manufacturing. In this study, micro tools (WC) to produce micro structures and parts were manufactured by cylindrical grinding machine employing ELID (Electrolytic In-process Dressing) technique and the micro tools are fabricated as square shape with the dimension less than 100${\mu}{\textrm}{m}$. With the micro tools on the same machine, characteristics of micro grooving and drilling are evaluated. Also we compare normal micro machining with ultrasonic micro machining on the vibration table. It is confirmed that the developed micro tools are fully applicable to micro grooving, micro drilling and free form cutting.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.245-250
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• 2002

A successful on-line monitoring system for conventional machining operations has the potential to reduce cost, guarantee consistency of product quality, improve productivity and provide a safer environment for the operator. In fee-shape machining, typical signs of tool problems such as vibration, noise, chip flow characteristics and visual signs are almost unnoticeable without the use of special equipment. These characteristics increase the importance of automatic monitoring in fine-shape machining; however, sensing and interpretation of signals are more complex. In addition, the shafts of the micro-tools break before the typical extensive cutting edge of the tool gets damaged. In this study, the existence of a relationship between the characteristics of the cutting force and tool usage was investigated, and tool breakage detection algorithm was developed and the fellowing results are obtained. In data analysis, didn't use a relative error compare which mainly used in established experiment and investigated tool breakage detection algorithm in time domain which can detect AE and cutting force signals more effective and accurate.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.7
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• pp.94-100
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• 1999

This study adopted the ultra precision machining system which was composed of an air bearing spindle, a granite bed, air pad and a linear feeding mechanism. It also applied the cutting experiment on the aluminum alloy. To evaluate the safety of high speed machining, we examined the surface roughness according to the changes of cutting speed and obtained the speed limit. This paper also studied the effect of cutting condition such as feed rates and depths of cut on the surface roughness within the speed limit. This provided practical information regarding ultra precision machining.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.352-357
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• 2001

In this study, residual stress was investigated to evaluate damaged layer in high speed machining through simulation. In machining steel(STDll), residual stress remaining in machined surface was mainly appeared as compressive stress. The scale of this damaged layer more depends on feed per tooth and radial depth than spindle speed. Damaged layer was measured by optical microscope and hardness method. The micro-structure of damaged layer was a martensite because of cutting force and cutting temperature. Thickness of damaged layer is increased with incresing of feed per tooth and radial depth.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.5
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• pp.65-71
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• 1998

This paper presents in-process compensation methodology to eliminate cutter runout and improve machined surface quality. The cutter runout compensation system consists of the micro-positioning mechanism with the PZT (piezo-electric translator) which is embeded in the sliding table to manipulate the radial depth of cut in real time. For the implementation of cutter runout compensation methodology. cutting force adaptive control was proposed in the angle domain based upon PI (proportional-integral) control strategy to eliminate chip-load change in end milling process. Micro-positioning control due to adaptive acuation force response improves the machined surface quality by compensation or elimination of cutter runout induced cutting force variation. This results will provide lots of information to build-up the precision machining technology.

• Geomechanics and Engineering
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• v.13 no.6
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• pp.977-995
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• 2017

It is well accepted that rock failure mechanism influence the cutting efficiency and determination of optimum cutting parameters. In this paper, an attempt was made to research the factors that affect the failure mechanism based on discrete element method (DEM). The influences of cutting depth, hydrostatic pressure, cutting velocity, back rake angle and joint set on failure mechanism in rock-cutting are researched by PFC2D. The results show that: the ductile failure occurs at shallow cutting depths, the brittle failure occurs as the depth of cut increases beyond a threshold value. The mean cutting forces have a linear related to the cutting depth if the cutting action is dominated by the ductile mode, however, the mean cutting forces are deviate from the linear relationship while the cutting action is dominated by the brittle mode. The failure mechanism changes from brittle mode with larger chips under atmospheric conditions, to ductile mode with crushed chips under hydrostatic conditions. As the cutting velocity increases, a grow number of micro-cracks are initiated around the cutter and the volume of the chipped fragmentation is decreasing correspondingly. The crack initiates and propagates parallel to the free surface with a smaller rake angle, but with the rake angle increases, the direction of crack initiation and propagation is changed to towards the intact rock. The existence of joint set have significant influence on crack initiation and propagation, it makes the crack prone to propagate along the joint.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.326-331
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• 2000

In this study, residual stress was investigated experimentally to evaluate damaged layer in high-sped machining. In machining difficult-to-cut material, residual stress remaining in machined surface was mainly speared as compressive stress. The scale of this damaged layer depends upon cutting speed, feed per tooth and radial cutting depth. Damaged layer was measured by optical microscope. The micro-structure of damaged layer was a mixed maternsite and austenite. depth of damaged layer is increased with increasing of cutting temperature, cutting force and radial depth. On the other hand, that is slightly decreased with decreasing of cutting force. The increase of tool wear causes a shift of the maximum residual stress in machined surface layer.