• Proceedings of the KSME Conference
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• 2008.11a
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• pp.464-468
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• 2008

In most of the passenger side airbag door in hard type IP today is designed with invisible tear-seam line. In order to design the tear-seam invisible, the tear-seam must be designed with required RWT (residual wall thickness) that is just thick enough to be broken by the PAB pressure on deployment and not by other surrounding impact forces. Hence, keeping the right optimum opening force is very important, and finding the right RWT became the key in designing the tear-seam. The study conducted in this paper describes the search for the optimum RWT around the tear-seam by using finite element method and the optimum RWT is suggested for milling type tear-seam having V-shape cross-section.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.5
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• pp.391-399
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• 2017

This paper presents the effects of the cutting speed and feed rate on the axial shape of flat end-milled down cut side walls. Experiments were performed using the cutting speed, tool diameter, and feed per tooth as variables, and the thrust force and axial shape were measured as the experimental results. The results of this study confirmed that a smaller feed per tooth, which is proportional to the value obtained by dividing the feed rate by the cutting speed, results in a higher axial shape accuracy. In addition, the axial shape can be simplified to a form in which two straight lines having different slopes meet at a singular point. Therefore, it was concluded that the shape accuracy could easily be estimated during the operation and improved by adjusting the feed per tooth.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.547-552
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• 2003

In mold machining, there are many concave machining regions where chatter and tool deflection occur since MRR (material removal rate) increases as curvature increases even though cutting speed and depth of cut are constant. Boolean operation between stock and tool model is widely used to compute MRR in NC milling simulation. In finish cutting, the side step is reduced to about 0.3mm and tool path length is sometimes over 300m. so Boolean operation takes long computation time and includes much error if the resolution of stock and tool model is larger than the side step. In this paper, curvature of CL(cutter location) surface and side step of tool path is used to compute the feedrate for constant MRR machining. The data structure of CL surface is Z-map generated from NC tool path. The algorithm to get local curvature from discrete data was developed and applied to compute local curvature of CL surface. The side step of tool path was computed by point density map which includes cutter location point density at each grid element. The feedrate computed from curvature and side step is inserted to new tool path to regulate MRR. The resultants wire applied to feedrate optimization system which generates new tool path with feedrate from NC codes for finish cutting. The system was applied to speaker mold machining. The finishing time was reduced to 12.6%. tool wear was reduced from 2mm to 1.1mm and chatter marks and over cut on corner were removed.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2007.11a
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• pp.1313-1317
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• 2007

Manufacturing condition is one of the most important factors in precision manufacturing. In this study, we optimized minimizing the Z vibration acceleration using RSM(response surface methodology) by table of orthogonal array. RSM was well adapted to make the analytical model of the minimum vibration acceleration and enable the objective function to be easily created and a great deal of the time in computation to be saved. Therefore, it is expected that the proposed optimization procedure using RSM can be easily utilized to solve the optimization problem of manufacture condition.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.171-176
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• 2012

So far, carbide insert production technology was carried out using a diamond grinding wheel. This production technology has problem that raise production costs and decrease in productivity. The SIDE PRESS method to solve this problem have been developed. In this paper, the machining characteristics of lateral chip breaker turning inserts produced by the SIDE PRESS method was studied. The cutting force and the resulting surface roughness were measured at various cutting conditions. The experimental results indicate that the chip breaker inserts of three-dimensional geometry is the best cutting performance.

• Design & Manufacturing
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• v.17 no.1
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• pp.7-12
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• 2023

Recently, with the emergence of the 4th industrial revolution, the demand for smart factories and factory automation is increasing. In this study, a tool life prediction program was developed to select optimal machining conditions using CNC milling equipment, which is widely used in flexible production and automation. The equipment used in the experiment was Hwacheon Machine Tool's 5-axis machining equipment, and the tool used was a 17F2R tool. For the machining path, the down-milling cutting method was selected and long-term machining was performed. The analysis standard for side wear on the tool was set at 0.1 to 0.2 mm, and tool life data and wear data were obtained in the cutting experiment. The program was created through the data obtained from the experiment, and a prediction rate of over 90% was secured when comparing the experimental data and the predicted data.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.4
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• pp.39-47
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• 2004

In mold machining, there are many concave machining regions where chatter and tool deflection occur since MRR(material removal rate) increases as curvature increases even though cutting speed and depth of cut are constant. Boolean operation between stock and tool model is widely used to compute MRR in NC milling simulation. In finish cutting, the side step is reduced to about 0.3mm and tool path length is sometimes over loom, so Boolean operation takes long computation time and includes much error if the resolution of stock and tool model is larger than the side step. In this paper, curvature of CL (cutter location) surface and side step of tool path is used to compute the feedrate for constant MRR machining. The data structure of CL surface is Z-map generated from NC tool path. The algorithm to get local curvature from discrete data was developed and applied to compute local curvature of CL surface. The side step of tool path was computed by point density map which includes cutter location point density at each grid element. The feedrate computed from curvature and side step is inserted to new tool path to regulate MRR. The resultants were applied to feedrate optimization system which generates new tool path with feedrate from NC codes for finish cutting. The system was applied to the machining of speaker and cellular phone mold. The finishing time was reduced to 12.6%, tool wear was reduced from 2mm to 1.1mm and chatter marks and over cut on corner were reduced, compared to the machining by constant feedrate. The machining time was shorter to 17% and surface quality and tool was also better than the conventional federate regulation using curvature of the tool path.

• The Journal of Korean Academy of Prosthodontics
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• v.48 no.4
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• pp.294-300
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• 2010

Purpose: The template-guided implant surgery offers several advantages over the traditional approach. The purpose of this study was to evaluate the accuracy of coordinate synchronization procedure with 5-axis milling machine for surgical template fabrication by means of reverse engineering through universal CAD software. Materials and methods: The study was performed on ten edentulous models with imbedded gutta percha stoppings which were hidden under silicon gingival form. The platform for synchordination was formed on the bottom side of models and these casts were imaged in Cone beam CT. Vectors of stoppings were extracted and transferred to those of planned implant on virtual planning software. Depth of milling process was set to the level of one half of stoppings and the coordinate of the data was synchronized to the model image. Synchronization of milling coordinate was done by the conversion process for the platform for the synchordination located on the bottom of the model. The models were fixed on the synchordination plate of 5-axis milling machine and drilling was done as the planned vector and depth based on the synchronized data with twist drill of the same diameter as GP stopping. For the 3D rendering and image merging, the impression tray was set on the conbeam CT and pre- and post- CT acquiring was done with the model fixed on the impression body. The accuracy analysis was done with Solidworks (Dassault systems, Concord, USA) by measuring vector of stopping’s top and bottom centers of experimental model through merging and reverse engineering the planned and post-drilling CT image. Correlations among the parameters were tested by means of Pearson correlation coefficient and calculated with SPSS (release 14.0, SPSS Inc. Chicago, USA) ($\alpha$ = 0.05). Results: Due to the declination, GP remnant on upper half of stoppings was observed for every drilled bores. The deviation between planned image and drilled bore that was reverse engineered was 0.31 (0.15 - 0.42) mm at the entrance, 0.36 (0.24 - 0.51) mm at the apex, and angular deviation was 1.62 (0.54 - 2.27)$^{\circ}$. There was positive correlation between the deviation at the entrance and that at the apex (Pearson Correlation Coefficient = 0.904, P = .013). Conclusion: The coordinate synchronization 5-axis milling procedure has adequate accuracy for the production of the guided surgical template.

• Tribology and Lubricants
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• v.17 no.5
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• pp.365-372
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• 2001

This paper has been presented the hydrodynamic effect by the journal speed, eccentricity and source positions in order to overcome the defects of air bearing such as low stiffness and damping coefficient. Choosing the two row source position of air bearing is different from existed investigations in the side of pressure distribution of air film because of the high speed of journal and the wedge effects by the eccentricity. These optimal chooses of the two row source positions enable us to improve the performance of the film reaction force and loading force as making the high speed spindle. In this paper, The pressure behavior in theory of air film according to the eccentricity of journal and the source positions analyzed. The results of investigated characteristics may be applied to precision devices like ultra-precision grinding machine and ultra high speed milling.

• KSTLE International Journal
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• v.4 no.2
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• pp.66-72
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• 2003

This paper presents the hydrodynamic effect by the journal speed, eccentricity and source positions in order to overcome the defects of air bearing such as low stiffness and damping coefficient. Choosing the two row source position of air bearing is different from existing investigations in the side of pressure distribution of air film because of the high speed of journal and the wedge effects by the eccentricity. These optimal choices of the two row source positions enable us to improve the performance of the film reaction force and loading force as making the high-speed spindle. In this paper, The pressure behavior in theory of air film in high speed region of journal according to the eccentricity of journal and the source positions analyzed. The theoretical analysis has been identified by experiments. The results of investigated characteristics may be applied to precision devices like ultra-precision grinding machine and ultra high-speed milling.