• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.918-921
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• 2002

Some investigators who have tried to achieve the highly smooth surface finish using electrochemical processes have reported that high current density produced lustrous surfaces while the opposite conditions produced a passive layer and had a tendency to produce a black surface. However, processing at a low current density may produce a non-lustrous surface but the improvement of dimensional accuracy of the surface is significant. The surface with pulse process was a bit more lustrous than with continuous current but the black passive layer still could be found at grooved surface. There are two ways to achieve highly smooth surface finish. One is brushing it with a brush the other is electrochemical machining (ECM) with high current. The former method is the most common polishing practice, but not only may the surface obtained differ from operator to operator, but precision smooth surface on micro grooves are difficult to obtain. The latter one recently has been used to produce a highly smooth surface after EDM process. However, the material removal rate in ECM with high current is relatively high. Hence the original shape of the micro grooves, which was formed by electrochemical micro-machining (EMM) process, may be destroyed. In this study, an electrochemical polishing process using pulse current is adopted as a possible alternative process when micro grooves formed by EMM process should be polished. Mirror-like micro grooves with lustrous and smooth surface can be produced electrochemically with pulse current because the voltage and current used can be lower than the case of continuous current. This study will discuss the accurate control of physical and electrical conditions so as to achieve mirror-like micro grooves with lustrous and smooth surface without destroying the original shape of micro grooves.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.625-628
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• 2005

For precise micro-grooving and surface machining, ultrasonic cyclic elliptical cutting is proposed using two parallel piezoelectric actuators. The piezoelectric actuators are energized by sinusoidal voltages of varying phase which is essenstial to generating elliptical cutting. Experimental setup is composed of ultrasonic motor, single crystal diamond cutting tool, and precise motorized xyz stage. It is confirmed experimentally that the cutting performance, in terms of the cutting force, the burr formation, and the discontinuous chip formation is improved remarkably by applying ultrasonic elliptical vibration cutting.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.76-79
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• 2003

Glass molding is an advantageous method to manufacture glass micro optical components. However, it is difficult to make tungsten carbide core for glass molded micro optics way. We have developed novel method to fabricate tungsten carbide core for glass molding of glass micro optical components. Silicon masters were fabricated by micro machining. Tungsten Carbide cores were fabricated by forming, sintering and coating. Finally we fabricated glass molded V-groove with pitch of 192$\mu\textrm{m}$ and glass microlens way with lens diameter of 36∼225$\mu\textrm{m}$ by the present method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.6
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• pp.91-97
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• 2019

Rotating machining unit is a revolutionary product that can process worm shaft or spiral shaft with fast and precise, a rotary type cutting tool, which is attached to automatic lathe and processes spiral groove on outer circumference of round bar. In this work, a study on micro tooth shape modification method of driving gear train in the rotating machining unit was presented. To observe the effect on power transmission characteristics of the driving gear pair, visualize the gear meshing condition and the load distribution on the gear teeth by using the professional gear train analysis program RomaxDesigner. By comparing the repeated analysis results, the effect of micro tooth shape modification on power transmission characteristics on driving gear can be summarized. The optimized gears were fabricated and measured by precision tester as a validation in this research.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.963-966
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• 2000

Plasma display panel (PDP) is a type of flat panel display utilizing the light emission that is produced by gas discharge. Barrier Ribs of PDP separating each sub-pixel prevents optical and electrical crosstalk from adjacent sub-pixels. Mold for forming barrier ribs has been newly researched to overcome the disadvantages of conventional manufacturing process such as screen printing, sand-blasting and photosensitive glass methods. Mold for PDP barrier ribs have stripes of micro grooves transferring stripes of glass-material wall. In this paper. Stripes of grooves of which width 48 um, depth 124um, pitch 274um was acquired by machining the material of WC with dicing saw blade. Maximum roughness of the bottom and sidewall of the grooves was respectively 120 nm, 287 nm. Maximum tilt angle caused by difference between upper-most width and lower-most width was 2$^{\circ}$. Maximum Radius of curvature of bottom was 7.75 ${\mu}{\textrm}{m}$. This results meets the specification for barrier ribs of 50 inch XGA PDP. Forming the glass paste will be followed by using mold in the near future.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.3
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• pp.34-40
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• 2003

This paper describes evaluation and monitoring methods of machining characteristics for developed micro grooving machine. Experiments were conducted under various process conditions such as spindle revolution speed, feed rates and depth of groove V and U shape of blade and STD11 were used in this experiment. The status of grooving was evaluated through analysis of the Acoustic emission (AE) signal resulted in each process condition. Based on the analysis, this paper examined the possibility of monitoring adapting fuzzy logic. In conclusion, this paper presented the possibility of monitoring in process adapting AE technology and appropriate micro grooving condition.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.1 s.94
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• pp.68-74
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• 1999

One of the recent changes in machining technology is rapid application of micro- and high precision grinding processes. A fine groove generation is necessary for the fabrication of optic, electronic and semiconductor parts, and achieved by chemical or mechanical processes. Slot grinding is very efficient for the generation of micro ordered groove with hard and brittle materials. As slot grinding is continuous, the ground depth become gradually shallow because of wheel wear. The form accuracy become worse from the increase of ground slot width by the loading phenomena at wheel side, results on chipping damage of the workpiece. The experiments achieve to the enhancement of the form accuracy and chipping free of the brittle materials using V shaped cast iron bonded diamond wheels. In this study we focused on the investigation of the effect of the high pressure air jet on the grinding characteristics. As a results, we found that the high pressure air jet is very effective on the reductions of the wheel wear, enhancement of the form accuracy.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.12 s.177
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• pp.184-189
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• 2005

An experimental study of the femtosecond laser machining of Si materials was carried out. Direct laser machining of the materials for the feature size of a few micron scale has the advantage of low cost and simple process comparing to the semiconductor process, E-beam lithography, ECM and other machining process. Further, the femtosecond laser is the better tool to machine the micro parts due to its characteristics of minimizing the heat affected zone(HAZ). As a result of line cutting of Si, the optimal condition had the region of the effective energy of 2mJ/mm-2.5mJ/mm with the power of 0.5mW-1.5mW. The polarization effects of the incident beam existed in the machining qualities, therefore the sample motion should be perpendicular to the projection of the electric vector. We also observed the periodic ripple patterns which come out in condition of the pulse overlap with the threshold energy. Finally, we could machined the groove with the linewidth of below $2{\mu}m$ for the application of MEMS device repairing, scribing and arbitrary patterning.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.499-500
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• 2006

The electrode wear in micro-EDM significantly deteriorates the machining accuracy. In this regard, electrode wear needs to be compensated in-process to improve the product quality. Therefore, there are substantial amount of research about electrode wear. In this study a control method for micro-EDM using discharge pulse counting is proposed. The method is based on the assumption that the removed workpiece volume is proportional to the number of discharge pulses, which is verified from experimental results analyzing geometrically machined volume according to various number of discharges. Especially, the method has an advantage that electrode wear does not need to be concerned. The proposed method is implemented to an actual micro-EDM system using high speed data acquisition board, simple counting algorithm with 3 axis motion system. As a result, it is demonstrated that the volume of hole machined by EDM drilling can be accurately estimated using the number of discharge pulses. In EDM milling process a micro groove without depth variation caused by electrode wear could be machined using the developed control method. Consequently, it is shown that machining accuracy in drilling and milling processes can be improved by using process control based on the number of discharge pulses.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1597-1600
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• 2005

Recently, the trends of TFT-LCD are large scale and thin thickness, so, the demands of Light Guide Panel(LGP) which is able to substitute for prism sheets are appeared. Functions of LGP obtaining polarization of light of the prism sheet as well as the incidence and reflection of light are demanded. This prismless type LGP to complete functions of the existing LGP and polarization at once must be supported by micro machining technology of LGP surface. In this research, we have used the STAMPER method for the mass product and In-Line process, and the optimized conditions are established by analyzing the cutting force and conditions according to the material and processing properties when the prismless type LGP mold is fabricated. Parameters of the cutting condition were the workpiece and cutting depth.