• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.417-422
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• 2000

In the process of die manufacturing, according to increasing demand of die and molds, the efficient machining of dies and molds has been increased. However, while the cutting process has been automated by the progress of CNC(computer numerical control) and CAD/CAM, the polishing process still depends on the experienced knowledge of an expert. Also, even when workers are skilled in polishing dies. it takes much time to obtain the required roughness and smoothness on the surface of a die. Moreover, many workers gradually avoid doing polishing work because of the poor working conditions caused by dust and noise. Therefore, to improve productivity and to solve the potential shortage of skilled workers, a user-friendly automatic polishing system was developed in this research. The developed polishing system with five degrees of freedom is able to keep the polishing tool normal to the die surface during operation and is able to maintain a pressure constantly by the developed pneumatic system. Also, to evaluate polishing performance of the developend system and find the polishing conditions, the various polishing experiments were carried out.

• International Journal of Precision Engineering and Manufacturing
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• v.3 no.4
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• pp.43-53
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• 2002

Polishing a die that has free-form surfaces is a time-consuming and tedious job, and requires a considerable amount of high-precision skill. In order to reduce the polishing time and cope with the shortage of skilled workers, a user-friendly automatic polishing system was developed. The polishing system is composed of two subsystems, a three-axis machining center and a two-axis polishing robot. The system has five degrees of freedom and is able to keep the polishing tool in a position normal to the die surface during operation. A sliding mode control algorithm with velocity compensation was proposed to reduce tracking errors. Trajectory tracking experiments showed that the tracking error can be reduced prominently by the proposed sliding mode control compared to a PD (proportional derivative) control. To evaluate the polishing performance of the polishing system and to and the optimal polishing conditions, the polishing experiments were conducted.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.8
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• pp.55-61
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• 2009

Recently, many studies are being conducted to realize high quality polishing technology, but because of high dependence on field experience and insufficient research for ultra-precision polishing technology, it is difficult to establish standardization of polishing conditions. The purpose of this study is to determine high-efficiency superfinishing conditions which are applicable in the field of machining. To achieve this, we have a developed a superfinishing device and conducted a series of polishing experiments for mechanical materials such as SM45C, Brass, Al7075, and Ti, from the perspective of oscillation speed, the rotational speed of the workpiece, contact roller hardness, contact pressure, and feed rate. From the experimental results, it was confirmed that the polishable superfinishing conditions range and efficient feed rate of polishing film can be determined.

• Design & Manufacturing
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• v.13 no.3
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• pp.12-18
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• 2019

Fluid jet polishing is a method of jetting a fluid to polish a concave or free-form surface. However, the fluid jet method is difficult to form a stable polishing spot because of the lack of concentration. In order to solve this problem, MR fluid jet polishing system using an abrasive mixed with an MR fluid whose viscosity changes according to the intensity of a magnetic field is under study. MR fluid jet polishing is not easy to formulate for precise optimal conditions and material removal due to numerous fluid compositions and process conditions. Therefore, in this paper, quantitative data on the factors that have significant influence on the machining conditions are presented using various simulations and the correlation studies are conducted. In order to verify applicability of the fabricated MR fluid jet polishing system by nozzle diameter, the flow pattern and velocity distribution of MR fluid and polishing slurry of MR fluid jet polishing were analyzed by flow analysis and shear stress due to magnetic field changes was analyzed. The MR fluid of the MR fluid jet polishing and the flow pattern and velocity distribution of the polishing slurry were analyzed according to the nozzle diameter and the effects of nozzle diameter on the polishing effect were discussed. The analysis showed that the maximum shear stress was 0.45 mm at the diameter of 0.5 mm, 0.73 mm at 1.0 mm, and 1.24 mm at 1.5 mm. The cross-sectional shape is symmetrical and smooth W-shape is generated, which is consistent with typical fluid spray polishing result. Therefore, it was confirmed that the high-quality surface polishing process can be stably performed using the developed system.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.1
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• pp.128-135
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• 2000

This paper presents a polishing expert system integrated with sensor information which can modify the polishing sequence and conditions initially determined by the system depending on the on-site polishing status. A practical system using AE sensor to detect the on-line polishing status is developed for the rotational polishing and the smoothly curved sur-face. Database and knowledge base for polishing processes are established by using the results of experiments and also expert's experience. Evaluations are performed for a die of headlight lamp by using both the sensor integrated expert sys-tem and the expert system without sensor. The test results show that the sensor integrated expert system provides more optimal polishing conditions since the proposed system takes advantage of on-line sensor information.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.10
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• pp.58-67
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• 1997

Generally, die polishing process occupies about 30 .approx. 50% of the whole die manufacturing time. However, die polshing has not been automated yet, since it needs a great deal of experience and skill. This study aims at development of an expert system for die polishing which gives such optimal parameters as tool and polishing conditions. Through experiments, polishing characteristics such as surface roughness, stock removal and scratch were analyzed quantitatively for each polishing tool, and a knowledge base for the expert system was established. Evaluation tests show that the developed system works well to suggest the optimal polishing conditions and it is very promising.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.2
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• pp.267-274
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• 2010

Recently, the magnetorheological (MR) polishing process has been examined as a new ultra-precision polishing technology for mirror surface generation in many applications, such as aspheric lenses, biochips, micro parts, etc. This method uses MR fluids which contains micro abrasives as a polishing media, and can. It is possible to obtain nano level surface roughness under suitable process conditions, however, required polishing time is highly dependent on the applied pre-polishing methods due to its very small material removal rate. Thus, in this study, a combined polishing method is presented to reduce total polishing time for SUS304. First, the electropolishing (EP) method was applied to obtain fine surface roughness, and the MR polishing was followed. Surface roughness variations were investigated according to the process conditions. As the results of this study, it was possible to reduce total polishing time for SUS304 using the proposed combined polishing method.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.139-144
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• 2004

This polishing machine has many advantages to polish complicated shaped molds due to spindle header with constant pressure. But, because of new polishing machine, there is no study of the standardization of polishing by polishing conditions yet. So we want to know the relation between polishing conditions(a kind of tool, grain size) and surface roughness. The result of experimental was obtained surface roughness of 0.061${\mu}{\textrm}{m}$ Ry in case of using wood tool and grain of 6${\mu}{\textrm}{m}$ diamond.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.10 s.175
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• pp.39-48
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• 2005

As the industrial development is accelerated, a new machining process and system are keenly required to achieve super precision surface finish. Especially to get ground surface finish fer complicated and narrow inner shape of molds, it is impossible with the existing methods so that a new method is being required to be developed. A new material, called Magic(MAGnetic Intelligent Compounds), is finally made and it is called Magic machining that uses this material. There is a way to make a material as follows, the mixture of magnetic particles, bonding material and particles of abrasive grain should be melt down by proper heat, and then this mixture put in a mold and cool down in magnetic field which has a uniform direction. This new polishing method is spotlighted as an excellent solution to the existing problems. However it hasn't reported any study about the influence of the machining conditions of polishing velocity, amplitude and polishing pressure to the surface roughness yet. This study would examine closely the influence of polishing conditions of the Magic polishing tool to the surface finish to decide the optimum polishing condition and to standardize the Magic polishing work.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.6
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• pp.136-141
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• 2015

Laser surface polishing is a polishing method for improving surface roughness using an integrated laser beam. Using a laser for surface polishing can improve the surface condition without physical contact or chemical action. Laser polishing has mainly been used to polish the surface of diamond or optical articles, such as lenses and glasses. Recently, diverse studies on laser polishing for metals have been conducted. The analytic study of laser surface polishing has been conducted with experimental trials for comparison, so that the proper conditions for laser polishing can be recommended. In this study, laser surface polishing was simulated in order to predict the heat-affected zone on the die steel depending on the power of the pulsed laser. The simulated results were verified by comparing them to those of the experimental trials. Through this study, therefore, the application of FEM to the selection of appropriate laser conditions could be possible.