• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2009년도 춘계학술대회 논문집
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• pp.383-384
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• 2009

• 한국정밀공학회지
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• 제19권8호
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• pp.63-70
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• 2002

In end milling process, the undeformed chip section area and cutting forces vary periodically with phase change of the tool. However the real undeformed chip section area deviates from the geometrically ideal one owing to cutter runout and tool shape error. In this study, a method of estimating the real undeformed chip section area which reflects cutter runout and tool shape error was presented in up end milling process using measured cutting forces. The average specific cutting resistance, Ka is defined as the main cutting force component divided by the modified chip section area. Ka value becomes smaller as the helix angle increases from $30^circC \;to\;40\circC$. But it becomes larger as the helix angle increases from $40^\circ$to 50 . On one hand, the Ka value shows a tendency to decrease with increase of the modified chip section area and this tendency becomes distinct with smaller helix angle.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회A
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• pp.1522-1525
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• 2007

Circular milling operations are used to enlarge die and cylinder bores, and machine airframe pockets. In this case, cutting force varies as cutting tool position relative to workpiece. This paper presents a mechanistic model of geometric uncut chip thickness by predicting time varying cutter-part intersection as the cutter travels along the circular path. Compared with experimental results, the suggested cutting force model shows a good agreement.

• 한국생산제조학회지
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• 제7권2호
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• pp.91-99
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• 1998

This paper presents a methodology for identifying the cutter runout geometry in end milling process. Cutter runout is common but undesirable phenomenon in multi-tooth machining because it introduces variable chip loading to insert which results in a accelerated tool wear. amplification of force variation and hence enlargement vibration amplitude From understanding of chip load change kinematics, the analytical cutting force convolution model was formulated as the angular domain convolution model was formulated as the angular domain convolution of three dynamic cutting force component functions. By virtue of the convolution integration property, the frequency domain expression of the local cutting forces and the chip width density of the cutter. Experimental study is presented to validate the analytical model. This study provides the in-process monitoring and compensation of dynamic cutter runout to improve machining tolerance and surface quality for industrial application.

• 대한기계학회논문집
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• 제19권9호
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• pp.2114-2121
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• 1995

Surface generation model of three types of endmills is introduced to analyse the cutting mechanism of an endmill more accurately. Superposition method is introduced to define the effective cusp including the effects of cutter mark. Through the comparison of three endmills, it is shown that the ball-nose endmill is superior to the ball endmill and the flat endmill for inclined milling process in 3-or 5-axis machining modes. By using the objective function minimizing the machining time, appropriate nose radius is selected for various cutter radiuses and cutter inclination angles.

• 한국정밀공학회지
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• 제15권5호
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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.

• 한국CDE학회논문집
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• 제9권1호
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• pp.35-43
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• 2004

It is well known that the five-axis machining has advantages of tool accessibility and machined surface quality when compared with conventional three-axis machining. Traditional researches on the five-axis tool-path generation have addressed interferences such as cutter gouging, collision, machine kinematics and optimization of a CL(cutter location) or a cutter position. In the paper it is presented that optimal CL data for a face-milling cutter moving on a tool-path are obtained by incorporating TSS(tool swept surface) model. The TSS model from current CL position to the next CL position is constructed based on machine kinematics as well as cutter geometry, with which the deviation from the design surface can be computed. Then the next CC(cutter-contact) point should be adjusted such that the deviation conforms to given machining tolerance value. The proposed algorithm was implemented and applied to a marine propeller machining, which proved effective from a quantitative point of view. In addition, the algorithm using the TSS can also be applied to avoid cutter convex interferences in general three-axis NC machining.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2002년도 춘계학술대회 논문집
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• pp.302-307
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• 2002

In end milling process, the undeformed chip section area and cutting forces vary periodically with phase change of the tool. However, the real undeformed chip section area deviates from the geometrically ideal one owing to cutter runout and tool shape error. In this study, a method of estimating the real undeformed chip section area which reflects cutter runout and tool shape error was presented during up-end milling of Inconel 718 using measured cutting forces. The specific cutting resistance, K. and $K_t$ are defined as the radial and tangential cutting forces divided by the modified chip section area. Both of $K_r$, and $K_t$ values become smaller as the helix angle increases from $30^\circ$ to $40^\circ$ Whereas they become larder as the helix angle increases from $40^\circ$ to $50^\circ$. On the other hand, the $K_r$, and $K_t$ values show a tendency to decrease with increase of the modified chip section area and this tendency becomes distinct with smaller helix angle.

• 한국공작기계학회논문집
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• 제11권5호
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• pp.45-52
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• 2002

In an end milling process, the undeformed chip section area and cutting forces vary periodically with the phase change of the tool. However, the real undeformed chip section area deviates from the geometrically ideal one owing to the cutter runout and tool shape error. In the current study, a method of estimating the real undeformed chip section area which reflects the cutter runout and tool shape error is presented during up-end milling processes of Inconel 718. The specific cutting forces, $K_r$ and $K_t$ are defined as the radial and tangential cutting forces divided by the modified chip section area, respectively. Both of the $K_{r}$ and $K_t$ values become smaller as the helix angle increases from $30^{\circ}$ to $40^{\circ}$. Whereas they become larger as the helix angle increases from $40^{\circ}$ to $50^{\circ}$. The $K_r$ and $K_t$ values show a tendency to decrease with increase of the modified chip section area.a.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2004년도 추계학술대회 논문집
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• pp.237-240
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• 2004

Indexable end mills, which consist of inserts and cutter body, have been widely used in roughing of parts in the mold industry. The geometry and distribution of inserts on cutter body are determined by application. This paper proposes analytical cutting force model for indexable flat end-milling process. Developed cutting force model uses the cutting-condition-independent cutting force coefficients and considers runout, cutter deflection and size effect for the accurate cutting force prediction. Unlike solid type endmill, the tool geometry of indexable endmill is variable according to the axial position due to the geometry and distribution of inserts on the cutter body. Thus, adaptive algorithm that calculates tool geometry data at arbitrary axial position was developed. Then number of flute, angular position of flute, and uncutchip thickness are calculated. Finally, presented model was validated through some experiments with aluminum workpiece.