• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.26 no.1
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• pp.13-19
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• 2017

In modern industry, the machining process is very important for manufacturing various products. More than 80% of machining processes apply rough cutting. The target of this study is to establish the optimal condition of rough cutting using trochoidal motion for improving productivity. For research, the range of cutting conditions is defined by trochoidal motion. The cutting time and tolerance are measured and evaluated according to the cutting conditions of machining. Experimental data are utilized for comparing trochoidal motion and contouring. It is found that the cutting time of trochoidal motion is two times less than that of contouring with optimal cutting conditions. To conclude, trochoidal motion for rough cutting under appropriate cutting conditions improves productivity and shortens processing time significantly.

• Journal of the Korean Society for Precision Engineering
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• v.11 no.6
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• pp.28-41
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• 1994

An efficient algorithm is proposed to select the proper tools and generate their paths for NC rough cutting of dies and molds with sculptured surfaces. Even though a milling process consists of roughing, semi-finishing, and finishing, most material is removed by a rough cutting process. Therfore it can be said that the rough cutting process occupy an important portion of the NC milling process, and accordingly, an efficient rough cutting method contributes to an efficient milling process. In order work, the following basic assumption is accepted for the efficient machining. That is, to machine a region bounded by a profile, larger tools should be used in the far inside and the region adjacent to relatively simple portion of the boundary while smaller tools are used in the regions adjacent to the relatively complex protion. Thus the tools are selected based on the complexity of the boundary profile adjacent to the region to be machined. An index called cutting path ratio is proposed in this work as a measure of the relative complexity of the profile with respect to a tool diameter. Once the tools are selected, their tool paths are calculated starting from the largest to the smallest tool.

• Korean Journal of Computational Design and Engineering
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• v.3 no.4
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• pp.236-242
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• 1998

This paper presents a development of computer aided cutting tool selection techniques for rough and finish turning operations. The developed system,. which is one of important activities for computer aided operation planning, firstly implements operation sequencing. Then, from relations of the size of machined area, recommended finishing allowance and maximum depth of cut, a main machining method is selected, a number of cut is calculated, cutting tools including toolholders and inserts are selected, and values for cutting parameters are determined. A cutting tool selection procedure is proposed for toolholders and inserts of ISO code in rough cutting, and some important parameters such as holder style, tool approach angle, tool function and its direction are described in detail. In order to demonstrate the validity of the system a case study is performed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.5
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• pp.129-134
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• 2013

Titanium used in industry has been widely applied for aerospace important parts and automobile important parts, etc. because the titanium is higher in strength compared to the steel and light in weight compared to the steel. This study is to investigate the effect of cutting tool cooling method and cutting time on the spindle speed and feed rate of vertical machining center as a parameter to find the rough cutting time in the medium speed cutting machining of the titanium alloy. It is found that the cutting machining heat are increased as the feed rate, cutting time and spindle speed are raised.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.5
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• pp.110-119
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• 1998

Dynamic cutting force variations in milling process were measured indirectly using spindle motor current. Magnitude of the spindle motor current is independent of cutting direction. Quasi-static sensitivity of the spindle motor current is higher than that of the feed motor current. Dynamic sensitivity of the spindle motor current is lower but cutting force was correctly represented by spindle RMS current in rough milling. In rough milling, chipping and tool fracture were well detected by the proposed tool fracture index using spindle motor current.

• Korean Journal of Computational Design and Engineering
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• v.18 no.4
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• pp.243-249
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• 2013

This paper presents a tool-path generation methods for an automated robotic system for skull drilling, which is performed to access to some neurosurgical interventions. The path controls of the robotic system are classified as move, probe, cut, and poke motions. The four motions are the basic motion elements of the tool-paths to make a hole on a skull. Probing, rough cutting and fine cutting paths are generated for skull drilling. For the rough cutting path circular paths are projected on the offset surfaces of the outer top and the inner bottom surfaces of the skull. The projected paths become the paths on the top and bottom layers of the rough cutting paths. The two projected paths are blended for the paths on the other layers. Syntax of the motion commands for a file format is also suggested for the tool-paths. Implementation and simulation results show that the possibility of the proposed methods.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.1
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• pp.53-64
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• 1994

Rouge cutting process takes the major portion of machining operation using NC milling machine. Especially, most of the machining time is spent in this process when molds are machined. Therefore, an efficient algorithm for generating the tool path for rough cutting is suggested in this paper. The first step of the procedure is getting the volume to be machined by applying the Boolean operation on the finished model and the workpiece which have been modeling system. Basic principle of determining machining procedure is that a large tool should be used at the portion of the simple shape while a small tool should be used at the complex portion. This principle is realized by representing the volume to be machined by an octree, which is basically a set of hexahedrons, and matching the proper tools with the given octants. When the tools are matched with the octants, the tool path can be derived at the same time.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.416-421
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• 2004

Off-line feedrate scheduling is presented as the advanced technology to regulate cutting forces at the desired level through change of feedrates. In rough cutting, the feedrate scheduling aims at reducing the machining time, which is the most important factor for better productivity. Thus, the largest force which can avoid breakage of tool shank and tooth is a reference force for feedrate scheduling in rough cutting. In this paper, a calculation method of the reference cutting force for feedrate scheduling is developed. This model calculates rupture plane of tooth using the FEM analysis of a tool and computes the reference force using the transverse rupture strength of a tool. Experiments validate that the presented feedrate scheduling model reduced machining time drastically and regulate cutting forces at the reference cutting force.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.11
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• pp.1958-1966
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• 2003

Three-axis CNC surface machining entails a series of processes including rough cutting, intermediate cutting and finish cutting for a reference surface defined in CAD/CAM. This study is targeting development of an integrated NURBS surface interpolator that can incorporate rough, intermediate and finish cutting processes. In each process, volume to be removed and cutting condition are different according to the shape of a part to be machined and the reference surface. Accordingly, the proposed NURBS surface interpolator controls motion in real-time optimized for the machining conditions of each process. In this paper, a newly defined set of G-codes is proposed such that NURBS surface machining through CNC is feasible with minimal information on the surface composition. To verify the usefulness of the proposed interpolator, through computer simulations on NURBS surface machining, total machining time, size of required NC data and cutting force variations are compared with the existing method.

• Korean Journal of Computational Design and Engineering
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• v.2 no.1
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• pp.19-27
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• 1997

This paper presents rough cut tool path planning for the fewer-axis machine consisting of a three-axis CNC machine and a rotary indexing table. In the problem dealt with in this paper, the tool orientation is "intermediately" changed, distinguished from the conventional problem where the tool orientation is assumed to be fixed. The developed rough cut path planning algorithm tries to minimize the number of tool orientation (setup) changes together with tool changes and the machining time for the rough cut by the four procedures: a) decomposition of the machining area based on the possibility of tool interference (via convex hull operation), b) determination of the optimal tool size and orientation (via network graph theory and branch-and bound algorithm), c) generation of tool path for the tool and orientation (based on zig-zag pattern), and d) feedrate adjustment to maintain the cutting force at an operation level (based on average cutting force). The developed algorithms are validated via computer simulations, and can be also used in pure fiveaxis machining environment without modification.