• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.10a
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• pp.230-235
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• 2000

In this paper, a surface generation model is presented to simulate surface roughness profile in turning operation. The simulation model takes into account the effect of tool geometry, process parameters, rotational errors of spindle, and the relative vibration between the cutting tool and workpiece. The surface roughness profiles are simulated based on the surface-shaping system. The model has been verified by comparing the experimental values with the simulation values. It is shown that the surface simulation model can properly predict the surface roughness profile.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.10a
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• pp.466-470
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• 2000

Externally pressurized air journal bearing has been widely used in high-speed spindle system and precision machinery because of its characteristics such as substantially low frictional loss, low heat generation and averaging effect leading better running accuracy. But air journal bearing have a disadvantage of the low load capacity due to the low viscosity. In this paper, The air journal bearing design to overcome the defects of air bearing such as low stiffness and dimping coefficients was investigated theoretically.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.467-470
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• 2002

Internet provides the useful method to monitor the current states of the machine tool no matter where a personnel is monitoring them. In this paper, a monitoring method of the torque of the machine tool's spindle induction motor using internet is suggested. The torque of vector controlled induction motor is estimated without speed measuring sensor. Only stator currents are measured to estimate the magnetizing current which is used to calculate flux linkage, rotor velocity and motor torque. Graphical programming is used to implement the suggested algorithm, to monitor the torque of an induction motor in real time and to make the estimated torque monitored on client computers. To solve the fluctuation problem of estimated torque caused from instantly varying rotating speed of an induction motor, the rotating speed is reconstructed based on the measured current signals. Mechanical part of the machine tool is also reconstructed using the data obtained from preliminary experiments. Torque of the spindle induction motor is well monitored on the client computers with 3% error range under various cutting conditions.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.214-219
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• 2001

One of the major limitations of productivity and quality in metal cutting is the machining accuracy of machine tools. The machining accuracy is affected by geometric errors, thermally-induced errors, and the deterioration of the machine tools. Geometric and thermal errors of machine tools should be measured and compensated to manufacture high quality products. In metal cutting, the machining accuracy is more affected by thermal errors than by geometric errors. In this study, the compensation device and temperature-based algorithm have been presented in order to compensate thermal error of machine tools under the real-time. The thermal error is modeled by means of angularity errors of a column and thermal drift error of the spindle unit which are measured by the touch probe unit with a star type styluses, a designed spherical ball artifact, and five gap sensors. In order to compensate thermal characteristics under several operating conditions, experiments performed with five gap sensors and manufactured compensation device on the horizontal machining center.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.90-93
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• 2002

In view of reliability assessment, the failure mode analysis by performance tests for machine totals is researched in this study. First, the error analysis with circular movement test data is studied. The various errors and their origins are analyzed by error equations and related parts are investigated. Second, This paper deals with analysis of vibration testing fur machine tools spindle. The various frequency components are classified by FFT and order analysis. The simple measuring devices and error evaluation programs for tests are also developed.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.345-350
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• 1999

The effectiveness of software error compensation for thermally induced machine tool errors relies on the prediction accuracy of the pre-established thermal error models. The selection of optimal sensor locations is the most important in establishing these empirical models. In this paper, a methodology for the selection of optimal sensor locations is proposed to establish a robust linear model which is not subjected to collinearity. Correlation coefficient and time delay are used as thermal parameters for optimal sensor location. Firstly, thermal deformation and temperatures are measured with machine tools being excited by sinusoidal heat input. And then, after correlation coefficient and time delays are calculated from the measured data, the optimal sensor location is selected through hard c-means clustering and sequential selection method. The validity of the proposed methodology is verified through the estimation of thermal expansion along Z-axis by spindle rotation.

• Proceedings of the KSME Conference
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• 2000.11a
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• pp.548-553
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• 2000

A new design of cylindrical capacitive sensor(CCS) for the displacement measurement of precision active magnetic bearing(AMB) spindle is presented in this paper. This research is motivated by the problem that existing 4-segment CCS is still sensitive to the $3^{rd}$ harmonic component of the geometric errors of a rotor. The procedure of designing new CCS starts from the modeling and error analysis of CCS. The angular size of CCS is set up as a design parameter, and new 8-segment CCS is introduced to possess an arbitrary angular size. The optimum geometry of CCS to minimize the effect of geometric errors is determined through minimum norm approach. Experimental results with test rotors have confirmed the improvement in geometric error suppression.

• Transactions of the Korean Society of Mechanical Engineers
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• v.12 no.1
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• pp.163-172
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• 1988

An off-line Geometric Adaptive Control Scheme is applied to the milling machine to identify its guideway errors. In the milling process, the workpiece fixed on the bed travels along the guideway while the tool and spindle system is fixed onto the machine. The scheme is based on the exponential smoothing of post-process measurements of relative machining errors due to the tool, workpiece and bed deflections. The guideway error identification system consists of a gap sensor, a, not necessarily accurate, straightedge, and the numerical control unit. Without a priori knowledge of the variations of the cutting parameters, the time-varying parameters are also estimated by an exponentially weighted recursive least squares method. Experimental results show that the guideway error is well identified within the range of RMS values of geometric error changes between machining passes disregarding the machining conditions.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.11
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• pp.1621-1628
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• 2004

This paper proposes a design methodology for the robust observer using the eigenstructure assignment in multi-output systems so that the observer is less sensitive to the ill-conditioning factors such as unknown initial estimation error, modeling error and measurement bias in transient and steady-state observer performance. The robustness of the observer can be achieved by selecting the desired eigenvector matrix to have a small condition number that guarantees the small upper bound of the estimation error. So the left singular vectors of the unitary matrix spanned by space of the achievable eigenvectors are selected as a desired eigenvectors. Also, this paper proposes how to select the desired eigenvector based on the measure of observability and designs the observer with small gain. An example of a spindle drive system is simulated to validate the robustness to the ill-conditioning factors in the observer performance.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.4
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• pp.44-48
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• 2006

Recently, demand the ultra precision product which is increasing rapidly is used extensively frontier industry field such as semi-conductor, computer, aerospace, precision machine. Ultra precision processing is the portion that is very needed to NT in the field of mechanical engineering. The latest date, together with radical advancement of electronic and photonics industry, necessity of ultra precision processing is on the increase for the manufacture of various kernel parts those are connected with these industrial fields. Specially, require motion accuracy of high resolution of nm order in stroke of hundreds millimeters according as diameter of processing object great and processing accuracy rises. In this case ,the response speed absolute delay because inertial mass of moving part is very large. Therefore, real time motion error compensation becomes very hardly. In this paper, we used ultra precision cutting unit(UPCU) to cope such problem. a UPCU is designed and tested to obtain sub-micrometer from accuracy in diamond turning of flat surfaces. The thermal growth spindle error is compensated for real time using a UPCU driven by piezoelectric actuator along with a laser encoder displacement sensor.