• Journal of the Korean Society for Precision Engineering
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• v.20 no.10
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• pp.74-81
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• 2003

This paper describes that the micro-cutting of WC-Co using PCD (Polycrystalline Diamond) and PcBN (Polycrystalline Cubic Boron Nitride) cutting tools are performed with SEM(Scanning Electron Microscope) direct observation method. The purpose of this study is to present reasonable cutting conditions to obtain precise finished surface and machining efficiency. Summary of the results are shown below: (1) The thrust cutting forces tend to increase more than the principal forces as the depth of cut and the cuttlllg speed are increased preferably on orthogonal microcutting. (2) The tool wear in the flank face was formed larger than that in the rake face on orthogonal micro cutting. (3) The wear appearance for PCD tools is abraded by hard WC particles of the work materials, which lead diamond grain to be detached from the bond.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.209-214
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• 2002

Mechanical micro-engineering is an easy and cheap way to fabricate micro-structures. If the application of the conventional machining method using flat-end mill becomes available for the micro-manufacturing process, it will be advanced as an extension of the conventional machining process. In this study, micro-grooves cutting using flat-end mill(($\phi$8) was performed. The characteristics on flat-end milling was investigated to improve machinability of micro-grooves. The experiments were performed according to variations of spindle revolution, depth of cut, and feed rate. Machinability through various cutting conditions was evaluated by surface geometry, tool wear, and cutting force. The results show that micro V-grooves of width(pitch) 29${\mu}{\textrm}{m}$ were acquired by flat-end milling. The maximum and minimum roughness of the wall of grooves was 438 and 67nm, respectively

• Journal of the Korean Society for Precision Engineering
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• v.22 no.11 s.176
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• pp.151-158
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• 2005

Micro-machine tool is essential in the micro/meso cutting for the sake of saving of space, resources, and energy. In this research, a micro-turning lathe was fabricated with piezoelectric feed drive mechanism, and motion of each axis was generated by stepwise mechanism with two piezo actuators. The resolution to drive the axis was $0.05{\mu}m$ and position accuracy less than $2{\mu}m$ was assured. From the positioning experiment, piezo feed mechanism is good enough for the micro machine tools. Many fuming experiments were carried out with diamond-cutting tools to evaluate cutting capability of a machine tool. Continuous flow type chip could be obtained even if the cutting speed was very low due to small diameter of workpiece. However, thorough investigation about machineability in micro/meso cutting is inevitable to assure high quality surface roughness in micro machine tool.

• Journal of Mechanical Science and Technology
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• v.17 no.2
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• pp.239-245
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• 2003

Ultra precision diamond cutting is a very efficient manufacturing method for optical parts such as HOE, Fresnel lenses, diffraction lenses, and others. During micro cutting, the rake angle is likely to become negative because the tool edge radius is considerably large compared to the sub-micrometer-order depth of cut. Depending on the ratio of the tool edge radius to the depth of cut, different micro-cutting mechanism modes appear. Therefore, the tool edge sharpness is the most important factor which affects the qualities of machined parts. That is why diamond, especially monocrystal diamond which has the sharpest edge among all other materials, is widely used in micro-cutting. The majar issue is regarding the minimum (critical) depth of cut needed to obtain continuous chips during the cutting process. In this paper, the micro machinability near the critical depth of cut is investigated in micro grooving with a diamond tool. The experimental results show the characteristics of micro-cutting in terms of cutting force ratio (Fx/Fy), chip shape, surface roughness, and surface hardening nea. the critical depth of cut.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.6
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• pp.401-409
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• 2016

The formation of micro-burrs in micro-milling processes causes several problems related to productivity and surface integrity. It should be minimized and suppressed by effective monitoring of the cutting conditions. This paper presents the correlation between the micro-burr length and cutting signals in the micro-milling process of an Al alloy (Al6061-T6). The acoustic emission (AE) signals and cutting force signals are acquired during the experiments. The characteristics of the cutting signals are obtained by analyzing the AE root mean square value and resultant cutting force. In addition, the micro-burr length is measured according to the cutting conditions by analyzing a scanning electron microscopy image of the machined surface. The results of this study can be used to enhance the surface quality of micro parts.

• Design & Manufacturing
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• v.17 no.2
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• pp.22-26
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• 2023

As Light-Emitting Diodes(LEDs) continue to advance in performance, their application in automotive lamps is increasing. Automotive LEDs utilize light guides not only for aesthetics but also to control light quantity and direction. Light guides employ patterns of a few hundred micrometers(㎛) to regulate the light, and the surface roughness(Ra) of these patterns can reach tens of nanometers(nm). Given that these light guides are produced through injection molding, mold processing technology with high surface quality micro-patterns is required. This study serves as a preliminary investigation into the development of high surface quality micro-pattern processing technology. It examines the surface roughness of the workpiece based on the cutting direction of the pattern and the cutting fluid type when cutting micro-patterns on STAVAX steel using cubic Boron Nitride(cBN) tools. The experiments involved machining a step-shaped micro-pattern with a height of 60 ㎛ and a pitch of 400 ㎛ in a 22×22 mm area under identical cutting conditions, with only the cutting direction and cutting fluid type being varied. The machining results of four cases were compared, encompassing two cases of cutting direction(parallel to the pattern, orthogonal to the pattern) and two cases of cutting fluid type (flood, mist). Consequently, the Ra value was found to be the highest(Ra 128.33 nm) when machining with the flood type in parallel to the pattern, while it was the lowest(Ra 95.22 nm) when machining with the mist type orthogonal to the pattern. These findings confirm that there is a difference of up to 25.8 % in the Ra value depending on the cutting direction and cutting fluid type.

• Transactions of Materials Processing
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• v.15 no.9 s.90
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• pp.654-659
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• 2006

In this paper, the real shapes of micro tool deflection were observed. In micro endmilling process, micro tool deflection generates very serious problems in contrast to macro tool deflection. For analyzing the micro tool deflection, the trend of micro tool deflection was observed using real captured images in this paper. To get the real images of micro tool deflection, micro slot cutting processes were executed under cutting volume using micro endmill($Dia.\;200{\mu}m$) and real images of tool deflection were obtained during cutting processing by high-speed camera. Finally, the extent of tool deflection was calculated by the deflection angle according to cutting volume.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.934-937
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• 2001

It is well-known that the micro fabrication technology of micro parts are the high energy beam or silicon-based micro machining method such as LIGA Process, Laser machining, photolithography and etching technology. But, for fabricating complex 3-D structure it is better to use mechanical machining. This machining method by the mechanical machine tool with nanometer accuracy is getting attention in some field-especially micro optics machining such as grating, holographic lens, micro lens array, fresnel lens, encoder disk etc.. In this study, we survey the micro fabrication by mechanical cutting method and set up the mechanical micro machining system. And we carried out micro cutting experiments for micro parts with v-shape groove.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.181-184
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• 2002

In these day, fabrication technologies for micro parts become more important with the increase of interest on microsystem and developed through the various approaches in the whole world. Among these technologies; micro mechanical machining is one of the most effective methods for the fabrication of micro parts. In this study, we fabricated micro shafts using micro endmill and micromachining system and measured the cutting force at the process. Also, Based on the data, we simulated the deformation of micro shafts due to the cutting force. Through the simulation results, it was verified that the cutting force at the process is enough to cause dimensional error at the micro shafts.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.121-127
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• 2008

Micro end-milling has been becoming an important machining process to manufacture a number of small products such as micro-devices, bio-chips, micro-patterns and so on. Despite the importance of micro end-milling, many related researches have given grand efforts to micro end-milling phenomenon, for example, micro end-milling mechanism, cutting force modeling and machinability. This paper strongly concerned actual problem, micro tool deflection, which causes excessive machining errors on the workpiece. To solve this problem, machining error prediction method was proposed through a series of test micro cutting and analysis of their SEM images. An iterative algorithm was applied in order to obtain corrected tool path which allows reducing machining errors in spite of tool deflection. Experiments are carried out to validate the proposed approaches. In result, remarkable error reduction could be obtained.