• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.873-877
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• 1997

This paper presents experimental results to know the charcteristics of machined surface due to cutter runout. Cutter runout is a common but undesirable phenomenon in multi-tooth machining such as end-milling process because it introduces variable chip loading to insert which results in a accelerated tool wear, amplification of force variation and hence enargement vibration amplitude. To develop in-proess cutter runout compensation system, set-up the micro-positoning mechanism which is based on piezoelectric translator embeded in the work holder to manipulate the depth of cut in real-time. And feasibility test of system was done under the various experimental cutting conditions. This results provide lots of information to build-up the precision machining technology.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.2
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• pp.251-259
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• 2010

It is presented in this study a new efficient intelligent machining strategy, which can be used to remove the uncut volume at the boundary region of curved surfaces caused by cutter interference. The geometric form definitions and recognition of topological features of the surface triangulation mesh are used to generate cutter paths along successive and interconnected steepest pathways, that minimize the cusp height left after flat end milling. In order to machine the uncut volume gradually, the z-map cutter centers are adjusted to avoid cutter interference for the 6 kinds of avoidance types. And then, the generative subsequent paths are sequenced to determine the second step cutter paths for the next uncut volume. For the 2 kinds of test models with convex and concave surface region, the implemented software algorithm is evaluated by investigating the residual swelling of uncut volume for each machining step.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.10
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• pp.109-118
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• 1997

The purpose of this paper is to design cutter profiles for manufacturing rotors of screw compressor, which are based on universal milling machine. The surface profile of screw rotor which is helicoidal is derived as brief equation through the coordinates transformation of the section perpendicular to rotor axis. And the equations of contact lines between a cutter and the surface profile of screw rotor are derived. The computer program which can analyze the equation of contact lines numerically and design the cutter profiles of screw rotor is made, and verified through measuring screw rotors which are menufactured as the designed cutter by the computer program.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.5
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• pp.100-105
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• 2002

The comprehensive system analysis for contour milling operation and its error has performed in this study. The obtained experimental results were from the practical points of view. In down-milling operation the contour error curve illustrates bigger thean actual workpiece radius. The contour error increased when the cutter loads increased. Through the procedural evaluation, it could ascertain the characteristics of generation mechanics in circular contour machining error, and the weight of each factors.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.4
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• pp.13-18
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• 2003

This paper presents the in-process compensation to control cutter ronout and to improve the machined surface quality. Cutter ronout compensation system consists of the micro-positioning servo system with piezoelectric actuator which is embeded in the sliding table to manipulate radial depth of cut in real-time. Cutting force feedback control was proposed in the angle domain based upon repetitive learning control strategy to eliminate chip load variation in end milling process. Micro-positioning control due to adaptive actuation force response improves the machined surface quality by cutter ronout compensation.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.40 no.4
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• pp.164-170
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• 2017

The CNC machine tool field is showing a growing trend with the recent rapid development of manufacturing industries such as semiconductors, automobiles, medical devices, various inspection and test equipment, mechanical metal processing equipment, aircraft, shipbuilding and electronic equipment. However, small and medium-sized machining companies that use CNC machine tools are experiencing difficulties in increasingly intense competition. Especially, small companies which are receiving orders from 3rd or 4th venders are very difficult in business management. In recent years, company S experienced difficulty to make product quality and delivery time due to the ignorance of the processing method when manufacturing cooling plate jig made of SUS304 material used for cell phone liquid crystal glass processing. In order to solve these problems, we redesigned the process according to the size of our company and tried to manage all processes with quantified data. In the meantime, we have found that there is a need to improve the cutter process, which accounts for most of the machining process. Therefore, we have investigated the correlation between RPM and FEED of three cutters that have been used in the past. As a result, we found that it is the most urgent problem to solve the roughing process during the cutter operation which occupies more than 70% of the total machining. In order to shorten the machining time and improve the quality in machining of SUS304 cooling plate jig, we select the main factors such as price, tool life, maintenance cost, productivity, quality, RPM, and FEED and use AHP to find the most suitable milling cutter. We also tried to solve the problem of delivery, quality and production capacity which was a big problem of S company through experiment operation with selected cutter tool. As a result, the following conclusions were drawn. First, the most efficient of the three cutters currently available in the machining center has proven to be an M-cutter. Second, although one additional facility was required, it was possible to produce the existing facilities without additional investment by supplementing the lack of production capacity due to productivity improvement. Third, the Company's difficulties in delivery and capacity shortfalls have been resolved. Fourth, annual sales increased by KRW 109 million and profits increased by KRW 32 million annually. Fifth, it can confirm the usefulness of AHP method in corporate decision making and it can be utilized in various facility investment and process improvement in the future.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.12
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• pp.212-219
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• 1998

During machining of dies and molds with sculptured surfaces. the cutter contact area changes continuously and results in cutting force variation. In order to implement cutting force prediction model into a CAM system, an effective and fast method is necessary. In this paper. a new method is proposed to predict mean cutting force. The cutter contact area in the spherical part of the cutter is obtained using Z-map, and expressed by the grids on the cutter plane orthogonal to the cutter axis. New empirical cutting parameters were defined to describe the cutting force in the spherical part of cutter. Before the mean cutting force calculation, the cutting force density in each grid is calculated and saved to force map on the cutter plane. The mean cutting force in an arbitrary cutter contact area can be easily calculated by summing up the cutting force density of the engaged grid of the force map. The proposed method was verifed through the slotting and slanted surface machining with various inclination angles. It was shown that the mean force can be calculated fast and effectively through the proposed method for any geometry including sculptured surfaces with cusp marks and holes.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.9
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• pp.4149-4155
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• 2013

High speed machining for higher cutting speed and feedrate lead to a increase of surface quality and material removal rate. This paper presents a study of the influence of cutting conditions on the vibration characteristics obtained by machining with face milling cutter for high speed machining. In this paper, Taguchi experimental design method which is based on orthogonal array table was applied to study vibration characteristics with high speed face milling cutter. The experimental conditions used orthogonal array of $L_{27}(3^{13})$. In this work, design and analysis of experiments is conducted to study the effects of these parameters on the vibration by using the S/N ratio, analysis of variance. Four cutting parameters namely, feed rate, champer length, cutting speed, and depth of cut were optimized with consideration of vibration characteristics.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.3
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• pp.210-217
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• 2009

This paper presents the analytical prediction of stability lobes in milling. The stability lobes are obtained by measuring the frequency response function (FRF) of a machining center at the cutting point of the end mill cutter, identifying cutting constants, and approximating cutting force coefficients. The stability lobes are experimentally verified through cutting tests.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.3
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• pp.437-446
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• 2013

There have been numerous studies on end milling processes. However, these have been restricted to the application of tools for special cutting purposes. A side milling cutter can handle long, deep, and open slots in a more efficient manner, and it provides the best stability and productivity for this type of milling. In this paper, a method to predict the cutting forces in side milling is described, and simulated cutting forces are compared with those obtained by cutting experiments. In particular, the side milling process easily generates relative motion between the tools and the workpiece because it produces intermittent cutting forces that cause vibrations over a wide frequency range. Therefore, the application of a dynamic cutting model instead of a static cutting model is appropriate to forecast the cutting forces more accurately.