• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 춘계학술대회 논문집
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• pp.934-938
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• 2000

Built-up edge affects the surface integrity of the machined surface and tool wear. Tool geometry and cutting conditions are very important factors to remove BUE. In this paper, we optimized the geometry of the metal slitting saw .1nd cutting conditions to remove BUE by the experiment. In general, the metal slitting saw is plain milling cutter with thickness less of a 3/16 inch. This is used for cutting workpiece where high dimensional accuracy and surface finish are necessary. The experiment was planned with Taguchi method that is based on the orthogonal array of design factors(coating, rake angle, number of tooth, cutting speed, feed rate). Response table was made by the value of the surface roughness, the optimized tool geometry and cutting conditions through response table could be determined. In addition. the relative effect of factors were identified by the variance analysis. filially. coating and cutting speed turned out important factors.

• 한국정밀공학회지
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• 제13권1호
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• pp.53-61
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• 1996

A clear understanding of the surface formation mechanism due to cutting is very important to help produce a good quality surface. Much of the roughness along the length of a bar being cut in a lathe can be explained in terms of macroscopic tool shape and feed rate. However, the roughness along the direction of cutting requires a different explanation. The formation of surface roughness is a problem in flow and fracture of materials in the vicinity of the tool edge. On a microscopic scale the cutting edge is rounded because it is impossible to grind a perfectly sharp cutting edge. Even if a perfectly sharp cutting edge were obtained it would soon become dull as a result of rapid breakdown and wear of the cutting edge. A research project is proposed in which in the main object is to model the surface formation mechanism due to cutting. The tool was assumed to be dull, that is, its edge has a finite radius. In order to study the effect of the radius of cutting edge on the surface formation, tools having different cutting edges were used. For orthogonal cutting experiment, cast iron and glass were chosen as brittle materials. Plowing forces acting in the cutting edge were estimated and its effect on the surface roughness was studied by observing the machined surface using optical microscope.

• 대한기계학회논문집
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• 제7권2호
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• pp.161-167
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• 1983

In this study the phenomenon of cutting stress which arises on cutting tools and work pieces in cutting process is investigated by rake angle of cutting tools and feed for this measurement, P$_{s}$-1 (high modulus, photolastic Inc.) was used as a cutting tool, P$_{s}$-3 (medium modulus, photolastic Inc.) was used as work piece and reduction apparatus was attached to the head stock, and orthogonal cutting was adapted as a cutting method and transparent glass was used to block the strain in the orientation of thickness. The followings are the results of this study. (1) Photoelastic experimental equipments have made it possible to make dynamic measurement and analyze stress distribution in cutting tool and work piece surface which has hitherto been conducted only in static measurement and analyzing method. (2) The maximum stress arising at tools and work pieces in cutting process is on the tool edge tip, and the maximum stress arising on the tip of cutting tools is equal to that on the contacting area of work pieces in values. (3) The distributions of maximum shear stress on certain parts of the cutting tools and work pieces are as follows; for cutting tools, .alpha.=12.deg., .alpha.=0.deg., .alpha.=-12.deg. in order, and for work pieces, .alpha.=-12.deg., .alpha.=0.deg., .alpha.=12.deg. in opposite order.der.

• 한국윤활학회:학술대회논문집
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• 한국윤활학회 2002년도 proceedings of the second asia international conference on tribology
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• pp.321-322
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• 2002

This paper presents study of effects of cutting parameters such as cutting speed, feed rate and depth of cut on the surface roughness in hard turning. Taguchi Method and linear regression model of design parameters were utilized to identify the controlling process parameters that can monitor the surface roughness in the hard turning operation. In the process optimization, experimental planning was performed using the orthogonal array and concept of the signal-to-noise ratio. Cutting parameters such as speed, feed rate, and depth of cut were selected as process parameters and the ANOVA analysis showed that feed rate and cutting speed had more effect on the roughness variation that depth of cut.

• 한국생산제조학회지
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• 제23권6호
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• pp.569-575
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• 2014

In this study, the effect of cutting edge geometry, such as helix and rake angles, on surface roughness in ball-end milling is investigated by using the Taguchi method. A set of experiments adopting the $L_{27}(3^{13})$ design with an orthogonal array are conducted with special WC ball-end mills having different helix and rake angles. Analysis of variance (ANOVA) is performed to analyze the effects of tool geometry and machining parameters, such as cutting speed, feed per tooth, and depth of cut, on surface roughness. The ANOVA results reveal that helix and rake angles are critical factors affecting surface roughness; the interaction of helix angle and cutting speed is also important. This research can contribute to novel cutting edge designs of ball-end mills and optimization of cutting parameters.

• 한국정밀공학회지
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• 제12권12호
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• pp.72-80
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• 1995

Ultraprecision machining technology has been playing a rapidly increasing and important role in manufacturing. However, the physics of the micromachining process at very small depth of cut, which is typically 1 .mu. m or less is not well understool. Shear along the shear plane and friction at the rake face dominate in conventional machining range. But sliding along the flank face of the tool due to the elastic recovery of the workpiece material and the effects of plowing due to the large effective negative rake angle resultant from the tool edge radius may become important in micromachining range. This paper suggests an orthogonal cutting model considering the cutting edge radius and then quantifies the effect of plowing due to the large effective negative rake angle.

• 한국정밀공학회지
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• 제15권12호
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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.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2000년도 춘계학술대회논문집 - 한국공작기계학회
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• pp.270-276
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• 2000

Hard turning has the potential to replace grinding process and to achieve significant reduction in production time and cost. The main applications for hard turning is finishing process, namely grinding process. Therefore, it must be able to satisfy high surface integrity of the workpiece. This paper discusses surface quality in terms of residual stress and damaged layer with respect to cutting parameters in an intermittent hard turning. Damaged layer experiment is carried out orthogonal array. From that is based on the orthogonal array. From the response table, cutting parameters are analyzed from the view point of the damaged layer and residual stress. From this experimental results, even though in the intermittent hard turning, surface integrity turns out be good enough for replacing grinding process.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 1995년도 추계학술대회 논문집
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• pp.60-63
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• 1995

The behavior of the work materials in the chip-tool interface in extremely high strain rates and temperatures is more that of viscous liquids than that of normal solid metals. In these circumstances the principles of fluid mechanics can be invoked to describe the metal flow in the neighborhood of the cutting edge. In the present paper an Eulerian finite element model is presented that simulates metal flow in the vicinity of the cutting edge when machining a low carbon steel with carbide cutting tool. The work material is assumed to obey visco-plastic (Bingham solid) constitutive law and Von Mises criterion. Heat generation is included in the model, assuming adiabatic conditions within each element. the mechanical and thermal properties of the work material are accepted to vary with the temperature. The model is based on the virtual work-stream function formulation, emphasis is given on analyzing the formation of the stagnant metal zone ahead of the cutting edge. The model predicts flow field characteristics such as material velocity effective stress and strain-rate distributions as well as built-up layer configuration

• 한국정밀공학회지
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• 제18권12호
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• pp.130-136
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• 2001

Burrs formed during face milling operations are very hard to characterize because there are many parameters that affect the cutting process. Many researchers have tried to predict burr characteristics including burr size and shapes with various experimental conditions such as cutting speed, feed rate, in-plane exit angle, number of inserts, etc., but it still remains as a challenging problem for the complex combined effects between the parameters. In this paper, the Taguchi method, which is a systematic optimization application in design and analysis of experiments, is introduced to acquire optimum cutting parameters for burr minimization in face milling. Also, analysis of variance (AVOVA) is employed to study the performance characteristics in more detail. Experimental verifications are provided to show the effectiveness of this approach.