• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 춘계학술대회 논문집
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• pp.69-72
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• 2002

The geometry parameter of tool such as rake angle and clearance angle is defined clearly to solve the difference in communication between design and measurement stage. Using the developed simulation program, wheel is properly determined and end mill can be manufactured accurately. The performance test with well defined end mill provides sufficient information to decide optimal geometry. For machining hardened steel, end mills are designed and manufactured. Optimal rake angle and clearance angle is obtained from performance test. A specific software for automatic end mill production is developed far simulation and fur generation of NC code as Cad/CAM system.

• 한국정밀공학회지
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• 제16권4호통권97호
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• pp.229-236
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• 1999

The surface, generated by end milling operation, is deteriorated by tool runout, vibration, tool wear and tool deflection, etc. Among them, the effect of tool deflection on surface accuracy is analyzed. Surface generation model for the prediction of the topography of machined srufaces has been developed based on cutting mechanism and cutting tool geometry. This model accounts for not only the ideal geometrical surface, but also the deflection of tool due to cutting force. For the more accurate prediction of cutting force, flexible end mill model is used to simulate cutting process. Computer simulation has shown the feasibility of the surface generation system. Using developed simulation system, the relations between the shape of end mill and cutting conditions are analyzed.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 춘계학술대회 논문집
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• pp.788-793
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• 1997

The surface,generated by end milling operation, is deteriorated by tool runout,vibration,friction,tool deflection, etc. In many source,deflection of tool affects to surfave accuracy. To develop a surface accracy model,method for the prediction of the topography of machined surfaces has been developed based on models of machine tool kinematics and cutting tool geometry. This model accounts for not only the ideal geometrical surface, but also the deflection of tool resulted in cutting force. For the more accurate prediction of cutting force,flexible end mill model is used to simulate cutting process. Compute simu;ation have shown the feasibility of the surface generation system.

• 대한기계학회논문집
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• 제13권3호
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• pp.433-442
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• 1989

본 연구에서는 볼 엔드 밀 절삭실험을 통하지 않고 일반적인 선삭가공 등에서 쉽게 구할 수 있는 2차원 절삭 데이터를 이용하여 볼 엔드 밀의 기하학적 형상 및 절삭조건이 주어졌을 때 모든 볼 엔드 밀 가공에서의 절삭기구를 해석하고 절삭력 모델을 구하고자 한다. 이를 위하여 볼 엔드 밀의 기하학적 특성 및 절삭 조건 등을 분석하고, 미소절삭날터를 이용한 3차원 절삭해석방법을 적용하여 미소 절삭력을 구하고 이들의 합력으로서 절삭력을 계산한다.

• 한국정밀공학회지
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• 제21권6호
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• pp.43-51
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• 2004

A method for form error prediction in side wall machining with a flat end mill is suggested. Form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. Developed model can predict the surface form error about three hundred times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.

• 한국정밀공학회지
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• 제20권10호
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• pp.31-40
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• 2003

In this paper, optimal cutting condition to minimize the form error in side wall machining with a flat end mill is studied. Cutting forces and tool deflection are calculated considering surface shape generated by the previous cutting such as roughing. Using the form error prediction method from tool deflection, optimal cutting condition considering form accuracy is investigated. Also, the effects of tool teeth number, tool geometry and cutting conditions on form error are analyzed. The characteristics and the difference of generated surface shape in up and down milling are discussed and over-cut free condition in up milling is presented. Form error reduction method through successive up and down milling is also suggested. The effectiveness and usefulness of the presented method are verified from a series of cutting experiments under various cutting conditions. It is confirmed that form error prediction from tool deflection in side wall machining can be used in optimal cutting condition selection and real time surface error simulation for CAD/CAM systems. This study also contributes to cutting process optimization for the improvement of form accuracy especially in precision die and mold manufacturing.

• 한국정밀공학회지
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• 제14권4호
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• pp.38-45
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• 1997

A new dynamic model for the cutting process inb the end milling process is developed. This model, which describes the dynamic response of the end mill, the chip load geometry including tool runout, the dependence of the cutting forces on the chip load, is used to predict the dynamic cutting force during the end milling process. In order to predict accurately cutting forces and tool vibration, the model which uses instantaneous specific cutting force, inclueds both regenerative effect and penetration effect, The model is verified through comparisons of model predicted cutting force with measured cutting force obtained from machining experiments.

• 한국정밀공학회지
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• 제14권3호
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• pp.57-65
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• 1997

In this study, a cutting force in the Ball-end milling process is calculated using Z-map. Z-map can describe any type of cutting area resulting from the previous cutting geometry and cutting condition. Cutting edge of a ball-end mill is divided into infinitesimal cutting edge elements and the position of the ele- ment is projected to the cutter plane normal to the Z axis. Also the cutting area in the cutter plane is obtained by using the Z-map. Comparing this projected position with cutting area, it can be determined whether it engages in the cutting. The cutting force can be calculated by numerical integration of cutting force acting on the engaged cutting edge elements. A series of experiments such as contouring and upward/downward ramp cutting was performed to verify the calculated cutting force.

• 한국기계가공학회지
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• 제4권4호
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• pp.21-27
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• 2005

Recently researches for high speed machining have been actively performed. Few analytical studies, however, have been published. In this paper, a model of cutting forces is analytically studied to predict cutting characteristics in end mill process, especially considering both feed rate and spindle speed. The developed cutting model is based on Oxley's machining theory, which predicts the cutting forces from input data of workpiece material properties, tool geometry and cutting conditions. Experimental verification has been performed to verify the predictive cutting force model using tool dynamometer. It has been found that the simulation results substantially agree with experimental results.

• 한국정밀공학회지
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• 제14권3호
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• pp.66-74
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• 1997

In a high speed and high precision vertical machining center, chatter vibration is easily generated due to unbalanced masses in rotating parts and changtes of cutting forces. In this paper, modal test is performed to obtain modal parameters of the vertical machining center. In order to predit the cutting force of endmilling process for various cutting conditions, a mathematical model is given and this model is based on chip load, cutting geometry, and relationship between cutting forces and the chip load. Specific cutting constants of the model are obtained by averaging forces of cutting tests. The interactions between the dy- namic characteristics and cutting dynamics of the vertical machining center make the primary and the secondary feedback loops, and we make use of the equations of system to predict the chatter vibration. The chatter prediction is formulated as linear differential-differene equations, and simulated for several cases. Trends of vibration as radial and axial depths of cut are changed are shown and compared.