• Tribology and Lubricants
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• v.11 no.5
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• pp.99-107
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• 1995

This paper reported research results to develop an algorithm of on-lin evaluation of surface profiles and roughness generated by turning. The developed module consisted of computer simulation of surface profiles using mechanism of cutting mark formation and cutting vibrations, and online measurement of cutting vibrations. The relative cutting vibrations between tool and worpkiece were measured through an inductance pickup at the rate of one sample per rotation of the workpiece. The sampling process was monitored using an encoder to avoid conceling out the phase lag between waves. The digital cutting signals from the Analog-to-Digital converter were transferred to the simulation module of surface profile where the surface profiles were generated. The developed algorithm or surface generation in a hard turning was analyzed through computer simulations to consider the stochastic and dynamic nature of cutting process. Cutting tests were performed using AISI 304 Stainless Steel and carbide inserts in practical range of cutting conditions. Experimental results showed good correlation between the surface profiles and roughness obtained using the developed algorithm and the surface texture measured using a surface profilemeter. The research provided the feasibility to monitor surface characteristics during tribelogical tests considering wear effect on surface texture in machining.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.2
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• pp.111-117
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• 2016

The cutting performance of a developed small-angle spindle tool was investigated with Al6061 using a TiAlN coated high-speed steel end mill. Up-cut and down-cut processes in a milling machine were carried out at the range of 1000-4000 rpm for spindle speed and 50-300 mm/min for feed rate. As a result, the highest cutting force in the Fx direction was obtained from the up-cut process when the spindle speed was 1000 rpm and the feed rate was 100 mm/min. In the Fy direction, the highest cutting force appeared in the up-cut process at a feed rate of 250 mm/min at the same spindle speed. Conversely, the lowest cutting force came out in the up-cut process at a spindle speed of 4000 rpm and a feed rate of 50 mm/min. As for surface finish, the finest surface roughness was obtained as Ra 0.7642 um at a spindle speed of 4000 rpm and a feed rate of 50 mm/min. Consequently, given the cutting performance of the developed small-angle spindle tool, we conclude that its use in industrial practice is feasible.

• Korean Journal of Metals and Materials
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• v.48 no.7
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• pp.651-659
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• 2010

When high-speed interrupted cutting is carried out for die and mold steels with high hardness, CBN tools manifested a significantly longer wear life than carbide, ceramic, or cermet tools in an experiment of face milling characteristics. In addition, it was also found that they secured a stable surface roughness within a range of 1.6 S~6.3 S, an acceptable range for precision machining for polished machining parts. And it makes them acceptable in the precision machining field, except in industries where very high machining accuracy is required. In the high hardness interrupted cutting, it was advantageous to perform a negaland treatment and a honning treatment on the tools' cutting edge to extend tool life and surface roughness. Also, severe crater development was found on the sloped face in CBN tools following high-speed machining. This caused the cutting edge to be weakened and damaged, and ultimately resulted in a shorter tool life. Finally, as a result of EDX mapping inspection, Cr component was detected evenly on the entire crater wear area, which can be included only in STD 11.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.4 no.2
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• pp.31-37
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• 1995

This study is focused on the prediction of appropriate tool life by clarifying the correlation between progressive tool wear and AE signal. when rcutting SM45C by End mill in machining center. First of all, end mill have a problem that position of sensor sticking because it is revolution tool, but I think that it can be bained specific character according to sticking Sensor in the Vise. Consequently, the following results have been obtained; 1. Each cutting speed of feed rate over 0.1mm had a tendency to increase linearly according to the RMSAE 2. The level of AE signal at the same cutting area was more sensitive to depth of cut tharn the variation of feed rate 3. In the range of cutting duringqr about 75minqr atqr cutting speed 27m/min flankqr wear turns up aboutqr 0.21mm, aboutqr 0.29mm in the caseqr of about 65minqr at 33/min, qr hereby RMSAE increased rapidly at 0.2mm flank wear, also AE-HIT and CUM-CNTS.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.6 no.2
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• pp.102-111
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• 1997

This paper deals with the machinability based on turning of WC-Co allows with the coated and the sintered diamond tools. The main conclusions obtained are as follows. (1) When machining WC-10%Co alloy, the flank wear of sintered diamond tool increases more largely with the increase of cutting speed in comparison with coated diamond tool. The tool wear decreases with the increase of the grain size and nose radius of sintered diamond tool. (2) When machining WC-20%Co alloy, the tool wear and cutting force decrease with the decrease of rake angle. Their exists a certain cutting speed range to exhibit the smallest tool wear in machining the WC-20%Co alloy, and this critical cutting speed becomes higher by 2 times in the case of coated diamond tool compared with sintered diamond tool. (3) The machinability becomes better with the increase of Co content. The effects of cutting speed and feed rate on the roughness of machined surface become smaller with the increase of Co content.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.156-160
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• 1994

Use of engineering ceramics has been increasing due to the outstanding physical and chemical properties. Conventional machining processes, however, are not applicable due to their hardness and brittleness. Laser cutting is a promising alternative for these ceramics. In this study, experimental data of CO $_{2}$ laser cutting of $Al_{2}$ $O_{3}$ and Si $_{3}$ N $_{4}$ are obtained to give a guide in the industry. Results of $Al_{2}$ $O_{3}$ cutting showed extreme weakness to thermal crack and it was found that pulsed beam has to be used for thick $Al_{2}$ $O_{3}$ specimen. Si $_{3}$ N $_{4}$ showed good results for both CW and pulsed beams. Using pulsed beam resulted narrower kerf width with increased surface roughness a nd reduced cutting speed. It was also found that a parameter call path energy is useful for representing minimum threshold value for possible cutting range with pulsed beam.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.1
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• pp.69-77
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• 1993

Adaptive Control is applied to regulate cutting force in turning operation under varying cutting conditions. Regulation is achieved primarily by adjusting feedrate. Such control leads to better machine utilization and increased tool life. The modeling of adaptive control system in turning operation is presented. The experimental results show that the adaptive PI controller is stable and performs more effective force control over wide range of cutting conditions as compared with the fixed gain PI controller.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.18-23
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• 2002

In this paper, The torque of CNC spindle motor during machining is estimated without speed measuring sensor. The CNC spindle system is divided into two parts, the induction spindle motor part and mechanical part. In mechanical part the variation of the frictional force due to the increment of the cutting torque and the effect of damping coefficient is investigated. Damping coefficient is found to be a function of spindle speed and not influenced by the weight of the load, while frictional force is a function of both the cutting torque and spindle speed. Experimental formulars are drawn for damping coefficient as a function of spindle speed and frictional force as a function of both cutting torque and spindle speed respectively, to estimate the cutting torque accurately. Graphical programming is used to implement the suggested algorithm, to monitor the torque of an induction motor in real time. Torque of the spindle induction motor is well monitored with 3% error range under various cutting conditions.

• Journal of the Semiconductor & Display Technology
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• v.18 no.4
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• pp.62-68
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• 2019

The optoelectronic display units such as TFT-LCD or OLED require many thin optical plastic films and their mass manufacturing processes employ CO2 laser cutting of those thin films in a large quantity. However, laser film cutting could generate fume particles through melt shearing, vaporization, and chemical degradation and those particles could be of great concern for film surface contamination. In order to appreciate the fume particle dispersion behaviors in laser film cutting, this study relies on random particle simulations by probabilistic distributions of particle size, ejection velocity and angles coupled with Basset-Boussinesq-Oseen model of particle trajectory in low Reynolds number flows. Here, up to one million particles of random sampling have been tested to effectively show fume particles dispersed on the film surface. The computational results could show that particular range of fume particle size could easily disperse into the pixel region of processed optical films.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.38-47
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• 2002

Machining quality has been improved with the development of cutting tools. However, it is difficult to obtain a high degree of quality in machining a deep pocket with a long end mill, since machining accuracy is mainly dependent on the stiffness of the cutting tool and tool holder. To improve machining quality in machining a deep pocket using an end mill, the performance by cutting condition compare with others. Owing to this problem, it is necessary to select suitable tool and holder in the deep pocket machining. In this study, the hydraulic holder for the high speed machining is introduced and the performance of that is compared with others according to cutting conditions. The cutting parameters involved were; slenderness ratio in the range of 3 to 6 (L/D), radial depth of cut from 0.01 to 0.05 mm. Cutting force and surface roughness, precision of form were observed during the experiment to investigate cutting state.