• Korean Journal of Computational Design and Engineering
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• 제5권2호
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• pp.155-167
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• 2000

To be presented is two-dimensional chip-load analysis for cutting-load smoothing which is needed in unmanned machining and high speed machining of sculptured surfaces. Cutter-engagement angle and effective cutting depth are defined as chip-loads which are the geometrical measures corresponding to cutting-load while machining. The extreme values of chip-loads are geometrically derived in the line-line and line-arc-line blocks of the two-dimensional NC-codes. AFA(automatic feedrate adjustment) strategy for cutting-load smoothing is presented based on the chip-load trajectories.

• Journal of the Society of Naval Architects of Korea
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• 제30권1호
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• pp.1-9
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• 1993

Various geometric modeling techniques for a hull have been developed with wide application of computer to the ship design. Up to now, they are used for the representation of the sculptured surface with the piecewise polynominal curves or surfaces for a conventional hull. In this paper, a convenient and accurate modeling technique that is instancing and blending of the geometry primitives is introduced for a non-conventional hull such as SWATH, trimaran, caisson etc. Geometric characteristics, hydrostatic particulars and stability of the definded hull are calculated.

• Journal of the Korean Society for Precision Engineering
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• 제15권9호
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• pp.135-144
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• 1998

High speed machining is a key issue in die and mold manufacturing recently. Even though this technology has great potential of high productivity. tool wear accelerated by high cutting speed to the hardened materials is other barrier. In this research, we attempted to reduce tool wear by considering tool inclination angle between tool and workpiece. The boundary lines describing machined sculptured surfaces were represented by both of cutting envelop condition and the geometric relationship of successive tool paths. Chip cross section, and cutting length could be obtained from the calculated cutting edge and the rotational engagement angle. From the simulation results, machining inclination angle of tool of $15^\circ$ was good enough from the point of tool wear and cutting force, and this value was verified through the cutting experiment of high speed ball end milling.

• Journal of Korea Society of Industrial Information Systems
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• 제9권1호
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• pp.7-16
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• 2004

The tool path needs to be determined in an efficient manner to generate the final NC (numerical control) code for efficient machining. This is particularly important in machining free form pockets with an arbitrary wall geometry on a three-axis CNC machine. Many CAD/CAM systems use linear interpolation to generate NC tool paths for curved surfaces. However, this needs to be modified to improve the smoothness of the machined bottom surface, reduce machining time and CL (cutter location) file size. Curved machining can be a solution to reduce these problems. The unified rough and finish cut algerian and the tool motion is graphically simulated. In this paper, a grid based 3D navigation algorithm for generating NC tool path data for both linear interpolation and a combination of linear and circular interpolation for three-axis CNC milling of general pockets with sculptured bottom surfaces is developed.

• Journal of Korea Society of Industrial Information Systems
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• 제12권1호
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• pp.46-53
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• 2007

NC (Numerical Control) code for the tool path needs to be generated efficiently for machining of free form pockets with arbitrary wall geometry on a three axis CNC machine. The unified rough and finish cut algorithm and the tool motion is graphically simulated in Part 1. In this paper, a grid based 3D navigation algorithm simulated in Part 1 for generating NC tool path data for both linear interpolation and a combination of linear and circular interpolation for three-axis CNC milling of general pockets with sculptured bottom surfaces is experimentally performed and verified.

• Journal of the Korean Society for Precision Engineering
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• 제21권1호
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• pp.51-60
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• 2004

Ball-end milling is one of the most common manufacturing processes for the parts with sculptured surface. However, the conventional roughness model is not suitable for the evaluation of surface texture and roughness under highly efficient machining conditions. Therefore, a different approach is needed for the accurate evaluation of machined surface. In this study, a new method, named ‘Ridge method’, is proposed for the effective prediction of the geometrical roughness and the surface topology in ball-end milling. Theoretical analysis of a machined surface texture was performed considering the actual trochoidal trajectories of cutting edge. The characteristic lines of cut remainder are defined as three-types of ‘Ridges’ and their mathematical equations are derived from the surface generation mechanism of ball-end milling process. The predicted results are compared with the results of conventional method. The agreement between the results predicted by the proposed method and the values calculated by the simulation method shows that the analytic equations presented in this paper are useful for evaluating a geometrical surface roughness of ball -end milling process.

• Journal of the Korean Society for Precision Engineering
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• 제18권7호
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• pp.112-119
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• 2001

In modern manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are being designed and produced to meet various sophisticated functional specifications. The cutting force is required not only for the design of machine and cutting tools, but also for the determination of the cutting conditions for the various machining operations. The ball-end mill is deflected by the cutting force and, the tool deflection is one of the main reasons of the machining errors on a free-form surface. Hence, The cutting force generated in the ball-end milling is the most important property of the machining. The purpose of this study is to find the characteristics of the cutting force in inclined plane and the resultant machining errors in the ball-end milling process. Although the depth of cut is constant in the inclined plane, the cutting force area varies due to the hemisphere of the ball-end mill.

• Transactions of the Korean Society of Machine Tool Engineers
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• 제15권5호
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• pp.79-84
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• 2006

In modem manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are designed and produced. In the production of these complex-shaped mechanical components, e.g. automobile dies, molds, and various engineering applications, the ball-end milling process is one of the most widely used NC machining processes that consists of roughing, semi-finishing and finishing. In semi-finishing, cusps remained after roughing according to the used tools that have two patterns of stairs and wave shapes. These cusp shapes have air-cut in cutting and instability caused by high cutting speed that affects the cutting characteristics such as cutting force and tool wear. Cutting characteristics are measured and analyzed through cutting force, FFT analysis of cutting force and tool wear along cutting length according to low tool paths with same metal removal rate. As a results of the experiments, this study suggests the optimal conditions of tool path and cutting direction. This approach for the cutting characteristics of semi-finishing provides a useful aid for the productivity and efficiency improvements of NC machining processes.

• Journal of the Korean Society for Precision Engineering
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• 제21권4호
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• pp.57-63
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• 2004

This paper describes a method for digitizing the compound surfaces which are comprised of several unknown feature shapes such as base surface, and draft wall. From the reverse engineering's point of view, the main step is to digitize or gather three-dimensional points on an object rapidly and precisely. As well known, the non-contact digitizing apparatus using a laser or structured light can rapidly obtain a great bulk of digitized points, while the touch or scanning probe gives higher accuracy by directly contacting its stylus onto the part surface. By combining those two methods, unknown features can be digitized efficiently. The paper proposes a digitizing methodology using the approximated surface model obtained from laser-scanned data, followed by the use of a scanning probe. Each surface boundary curve and the confining area is investigated to select the most suitable digitizing path topology, which is similar to generating NC tool-paths. The methodology was tested with a simple physical model whose shape is comprised of a base surface, draft walls and cavity volumes.

• Transactions of the Korean Society of Mechanical Engineers
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• 제19권3호
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• pp.670-679
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• 1995

This paper presents the 3-D profile measurement system of live human faces, which was developed specially for 'KUMDORI sculptor robot' of the '93 Taejon Exposition. '93 Taejon EXPO. The basic principle for measurement adopts the slit beam projection which is a method of measuring 3-D surface profiles using geometric optics between the slit beam and the CCD camera. Since the slit beam projection consumes long measuring time, it is unfit to measure the 3-D profiles of living objects as human. Therefore, the projection type slit beam method which consumes short measuring time is newly suggested. And an algorithm to reconstruct the 3-D profile from the deformed images using finite approximated calibration is suggested and practically implemented. The projection type slit beam method was applied to spectators in a period of '93 Taejon EXPO. The measurement results show that the technique is suitable for 3-D face profile measurement on a living body.