• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2001년도 추계학술대회(한국공작기계학회)
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• pp.8-13
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• 2001

In the turning process, the feed is usually selected by a machining operator considering workpiece, cutting tool and depth of cut. Even if this selection can avoid power saturation or tool breakage, it is usually conservative compared to the capacity of the machine tools and can reduce the productivity significantly. This paper proposes a selection method of the feed and the reference cutting force based on MRR(material removal rate), maximum spindle power and specific energy. In order to estimate and control cutting force accurately in transient and steady state, this study utilizes a synthesized cutting force estimation method and a Fuzzy controller. The experimental results present that these systems can be useful for the FMS(flexible manufacturing system) and unmanned automation system.

• 대한기계학회논문집A
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• 제26권7호
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• pp.1446-1452
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• 2002

In the turning process, the feed is usually selected by a machining operator considering workpiece, cutting tool and depth of cut. Even if this selection can avoid power saturation or tool breakage, it is usually conservative compared to the capacity of the machine tools and can reduce the productivity significantly. This paper proposes a selection method of the feed and the reference cutting force based on MRR(material removal rate), maximum spindle power and specific energy. In order to estimate and control cutting force accurately in transient and steady state, this study utilizes a synthesized cutting force estimation method and a Fuzzy controller. The experimental results show that these systems can be useful for the unmanned turning process.

• Geomechanics and Engineering
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• 제31권3호
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• pp.249-263
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• 2022

The specially-shaped Polycrystalline Diamond Compact (PDC) cutter is widely used in drill bit design due to its advantages of high rock cutting efficiency, strong impact resistance and long service life in hard and abrasive formation drilling. A detailed understanding of rock cutting behavior of worn specially-shaped PDC cutter is essential to improve the drilling efficiency and decrease the drilling costs. In this paper, the theoretical models of two new principles (loading performance (LP) and cutting performance (CP)) are derived for evaluating the cutting process of worn specially-shaped cutter, the theoretical models consider the factors, such as cutter geometry, aggressiveness, stress state, working life, and rock cutting efficiency. Besides, the numerical model of heterogeneous granite is developed using finite element method combined with Voronoi tessellation, the LP and CP of 12 kinds of worn specially-shaped PDC (SPDC) cutters are analyzed. The results found that the mechanical specific energy (MSE) of worn cutters first increase and then decrease with increasing the cutting depth, and the MSE increase with the increase of back rake angle except for Conical cutter and Wedge-shaped cutter. From the perspective of CP, the worn PDC cutters are more suitable for the smaller cutting depths, and the back rake angle has little effect on the CP of the specially-shaped worn PDC cutters. Conical cutter, Saddle-shaped cutter and Ellipse-shaped cutter have the highest CP value, while Rhombus-shaped cutter, Convex cutter and Wedge-shaped cutter have the lowest value in selecting cutters. This research leads to an enhanced understanding of rock-breaking mechanisms of worn SPDC cutters, and provides the basis to select of specially-shaped PDC cutters for the specific target formation.

• 한국기계가공학회지
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• 제21권6호
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• pp.81-88
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• 2022

Titanium alloy (Ti-6Al-4V) has excellent mechanical properties and high specific strength; therefore, it is widely used in aerospace, automobile, defense, engine parts, and bio fields. Particularly in the aerospace field, as it has a low specific gravity and rigidity, it is used for the purpose of increasing energy efficiency through weight reduction of parts, and most have a thin-walled structure. However, it is extremely difficult to machine thin-walled shapes owing to vibration and deformation. In the case of thin-walled structures, the cutting forces and vibrations rapidly increase depending on the cutting conditions, significantly affecting the surface integrity and tool life. In this study, machining experiments on thin-wall milling of a titanium alloy (Ti-6Al-4V) were conducted for each experimental condition with different axial depths of cut, radial depth of cut, and machining sequence. The machining characteristics were analyzed, and an effective machining method was derived by a comprehensive analysis of the machined surface conditions and cutting signals.

• 대한기계학회논문집
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• 제16권7호
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• pp.1266-1277
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• 1992

본 연구에서는 공구의 형상과 절삭조건에 따른 공구의 결손형태를 예측하기 위하여 현재 가장 널리 쓰이고 있는 인볼류우트커터의 결손형태를 절삭날의 응력분포 값으로 예측하고 실험에 의하여 검증함과 동시에 기어 절삭실험을 통한 공구 결손의 성장거동을 고찰하였으며, 또한 마멸과 결손이 발생함에 따른 절삭력의 변화와 평형을 관찰하여 상호관련성을 비교함으로써 인볼류우트 기어커터의 초기 결손을 해석적으로 예측하였다.

• 한국정밀공학회지
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• 제15권4호
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• pp.141-147
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• 1998

A plastically deformed layer in the precision machined surface affects in various forms the physical properties of machined components such as the fatigue strength, the dimensional instability, microcracks and the stress corrosion cracking. These physical properties, so called surface integrity, are very important for designing highly stressed and critically loaded components. Typical plastic strains in the precision machined surface are very difficult to measure, since they are located within a very short distance from the surface and they change very rapidly. A new way is suggested to determine the residual strain in plastically deformed materials by analyzing the plastically deformed layer after a subsequent recrystallization process. This investigation is to explore a new technique for measuring plastic strain in machining applications, and in particular, to and the effect of cutting parameters(rake angle, depth of cut, specific cutting energy), on the plastic strains and strain energy.

• 터널과지하공간
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• 제23권1호
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• pp.54-65
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• 2013

선형절삭시험(Linear Cutting Machine)은 TBM(Tunnel Boring Machine)에서의 디스크 커터 설계와 굴진성능 예측을 위한 가장 신뢰성 있는 시험 중의 하나로서, 실대형 암석시료를 대상으로 실제의 커터 하중을 예측할 수 있는 장점을 갖고 있지만, 시료의 채취 및 운반이 용이하지 않고, 1회 시험에 많은 비용이 소요되는 단점을 갖고 있다. 최근 선형절삭시험이 갖는 이러한 경제적 시간적 제약점들을 극복할 수 있는 현실성 있는 수치모델의 개발에 관한 연구가 활발히 진행되고 있다. 본 연구에서는 3차원 입자결합모델을 이용하여 디스크 커터의 절삭에 의한 부산 응회암의 파쇄양상과 최적 커터간격을 도출하였다. 본 해석에서 분석된 비에너지는 $14.3MJ/m^3$ 일 때 최소값을 나타냈다. 이때의 최적의 s/p 비는 약 16 으로 분석되었으며, 부산응회암의 선형절삭시험 및 유한요소법에 의한 수치해석 연구결과와 유사한 경향을 나타냈다.

• Structural Engineering and Mechanics
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• 제86권1호
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• pp.119-137
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• 2023

The purpose of this research is to assess the performance of CBN and ceramic tools during the dry turning of gray cast iron EN GJL-350. During the turning operation, the variable machining parameters are cutting speed, feed rate, depth of cut and type of the cutting material. This contribution consists of two sections, the first one deals with the performance evaluation of four materials in terms of evolution of flank wear, surface roughness (2D and 3D) and cutting forces. The focus of the second section is on statistical analysis, followed by modeling and optimization. The experiments are conducted according to the Taguchi design L₃₂ and based on ANOVA approach to quantify the impact of input factors on the output parameters, namely, the surface roughness (Ra), the cutting force (Fz), the cutting power (Pc), specific cutting energy (Ecs). The RSM method was used to create prediction models of several technical factors (Ra, Fz, Pc, Ecs and MRR). Subsequently, the desirability function approach was used to achieve a multi-objective optimization that encompasses the output parameters simultaneously. The aim is to obtain optimal cutting regimes, following several cases of optimization often encountered in industry. The results found show that the CBN tool is the most efficient cutting material compared to the three ceramics. The optimal combination for the first case where the importance is the same for the different outputs is Vc=660 m/min, f=0.116 mm/rev, ap=0.232 mm and the material CBN. The optimization results have been verified by carrying out confirmation tests.

• 한국기계가공학회지
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• 제2권1호
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• pp.5-14
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• 2003

Cutting fluids used for superfinishing are usually mineral based oils With sulfur and chlorine additives. These cutting fluids are an environmental hazard and can adversely affect the health of personnel on the shop floor. The present investigation was undertaken to explore the possible alternative use of environmentally-conscious cutting fluids for superfinishing. Unlike mineral oils, these environmentally-conscious cutting fluids are biodegradable and non-hazardous. Experiments were conducted for testing an ester oil manufactured by Accu-Lube applied in miniscule amounts using the Minimum Quantity Lubrication (MQL) technique. A significant improvement in stock removal was found with the 6 stones tested. The specific energy values associated with the process were also significantly lower than those obtained previously with conventional straight oils and the water based synthetic fluid, indicative of better lubrication, while the surface roughness was comparable. These tests prove that MQL with ester oils can be a very effective environmentally-conscious alternative to conventional straight oils.

• 한국터널지하공간학회 논문집
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• 제10권2호
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• pp.139-152
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• 2008

본 연구에서는 TBM 디스크 커터의 암석절삭에 관하여 기존의 LCM시험을 모사하기 위한 수치해석을 실시하였다. 수치모사를 위하여 3차원 동적 파괴해석이 가능한 상용 프로그램인 AUTODYN-3D를 선정하였으며, 이를 통하여 각기 다른 4가지 이상의 커터간격 조건에 대해 수치해석을 수행하였다. 상기 프로그램 상에서 디스크 커터와 암석 시편을 3차원 형상으로 모델링 한 후, 8개 암종에 대해서 수치적 절삭시험을 진행하였다. 그 결과, 수치해석과 LCM시험에서 도출된 최적 커터간격은 대체로 일치하여, 추후 LCM시험결과를 보완할 수 있을 것으로 판단되었다. 그러나 등방성 암석에는 적용성이 매우 높았던 반면, 절리가 존재하거나 이방성을 가지는 암석의 경우에는 LCM시험결과와 비교하여 비에너지가 다소 크게 산출되었다. 따라서 이방성 암석의 모델링에 대한 추가적인 연구가 수반되어야 할 것으로 판단된다.