• Design & Manufacturing
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• 제17권2호
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• pp.22-26
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• 2023

As Light-Emitting Diodes(LEDs) continue to advance in performance, their application in automotive lamps is increasing. Automotive LEDs utilize light guides not only for aesthetics but also to control light quantity and direction. Light guides employ patterns of a few hundred micrometers(㎛) to regulate the light, and the surface roughness(Ra) of these patterns can reach tens of nanometers(nm). Given that these light guides are produced through injection molding, mold processing technology with high surface quality micro-patterns is required. This study serves as a preliminary investigation into the development of high surface quality micro-pattern processing technology. It examines the surface roughness of the workpiece based on the cutting direction of the pattern and the cutting fluid type when cutting micro-patterns on STAVAX steel using cubic Boron Nitride(cBN) tools. The experiments involved machining a step-shaped micro-pattern with a height of 60 ㎛ and a pitch of 400 ㎛ in a 22×22 mm area under identical cutting conditions, with only the cutting direction and cutting fluid type being varied. The machining results of four cases were compared, encompassing two cases of cutting direction(parallel to the pattern, orthogonal to the pattern) and two cases of cutting fluid type (flood, mist). Consequently, the Ra value was found to be the highest(Ra 128.33 nm) when machining with the flood type in parallel to the pattern, while it was the lowest(Ra 95.22 nm) when machining with the mist type orthogonal to the pattern. These findings confirm that there is a difference of up to 25.8 % in the Ra value depending on the cutting direction and cutting fluid type.

• 대한기계학회논문집A
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• 제26권9호
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• pp.1866-1873
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• 2002

The pipe-cutting machine developed in this study is a portable device used to cut a steel pipe. The machine, which is attached to the steel pipe by magnetic force, is moving around the pip e using four wheels. It also works for straight cutting of a steel plate. For the higher precision and labor time reduction, the automation of a pipe-cutting process is needed. However, it is not easily achieved because of vibrations and the loss of track. It is also found that the problems of the automation arise from the coupling of the functional requirements for the pipe-cutting machine. So, it is very difficult io solve the problems by a conventional design method. To overcome the difficulties the new design process for the pipe-cutting machine is established by axiomatic approach in this paper. Based on the Independence Axiom design process, a new product is designed and manufactured. Finally, it is verified by experiments that the performance of the automatic pipe-cutting machine is improved

• 한국정밀공학회지
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• 제25권6호
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• pp.40-46
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• 2008

Ultraprecision cutting of steels with geometrically defined single crystal diamond tools is handicapped by excessive tool wear. This paper presents a new approach to suppress the wear of single crystal diamond tool in cutting of steels. In general, it is said that the wear of diamond tool is caused by chemically reactive wear under high temperature and high pressure conditions. In order to suppress such chemical reactions, the time of contact between the diamond tool and the steel work in cutting was controlled by employing the intermittent cutting method such as fly-cutting. Series of intermittent cutting experiments have been carried out to control the tool-work contact time by changing one cycle of cutting length and cutting speed. The experimental results were shown that the tool wear was much dependent on the contact time regardless of the cutting speed, and that the wear was much suppressed by reducing the tool-work contact time. It is expected that the steels can be successfully cut with a single crystal diamond tool by controlling the contact time.

• 오토저널
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• 제14권6호
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• pp.105-112
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• 1992

The turning tests with sintered carbide tools have been conducted on typical high strength SSW2 railway wheel steel and its machinability were examined in terms of the cutting resistance, the roughness of turning surface, the chip disposal and others. Some results obtained in this paper are as follows: (1) The cutting resistance is not affected by the cutting speed (in this paper these were 23-78 m/min). (2) The roughness of finished surface is found to be largely dependent on cutting conditions and tool geometry. (3) There exists the explicit relates between the tool geometry cutting conditions (cutting speed, feedrate, and depth of cut) and independent variables(cutting resistance, surface roughness) are derived.

• 한국생산제조학회지
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• 제5권1호
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• pp.9-16
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• 1996

This is an experimental investigation of the temperature generated in a cutting tool during the machining of stainless steel. The temperature results from the wear of the cutting tool are considered in order to investigate the relation between cause and effect of these factors. This possibility has been tested using a thermocouple technique to record temperature vs. time curves for a variety of cutting conditions. This is done by employing a thermocouple inserted on the tool tip near the major cutting edge. Temperature distributions are calculated using finite element method and compared to the contour maps measured by an optical system. It suggests that the temperature gradients and the tool performance will be dependent on certain facotrs in tool geometry when cutting this material.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1992년도 춘계학술대회 논문집
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• pp.89-93
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• 1992

We experimented cutting characteristics-cutting force, behavior of chip, surface roughness-under low temperature, which generated by liquid nitrogen(77K). The results obtained are as follows; 1) The workpice is became to-195 .deg. C in 5, minutes, and in cooled cutting, cutting force bycooled workpices is stronger than normal temperature condition. Chip thickness is decreasing comparative toN.C and shear angle in shear plane is in creasing. 2) Chip formation becomes long or short tubular chips in turning SXM440, SNCM21 steel, when cutting speed is low and cutting temperatre is cooled condition, but in the STS304 steel the variation of c formations isn't known to. 3) In C.C, surface roughness of workpices is better than N.C and found to make more the crat wearthan N.C 4) It is possible to detect the behavior of chip by monitoring the maximum amplitude of gai value of cutting force.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 추계학술대회 논문집
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• pp.287-290
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• 2002

Stainless steel used widely in various fields of industry have the characteristics of difficulty-to-cut. This difficulty comes from its peculiarity, for example work hardening, vibration, etc. And these peculiarity on the cutting process have an effect on tool wear or life shortness of tools. To solve these problems several method have been developed. Hot-machining is one way of these method. when a material is heated, organization of material is soften. So cutting process becomes easy. When such a hot-machining method applies on drilling process and then heated material is processed, cutting force is less than usual drilling process cutting force. In this paper, cutting force is compared heated SUS 304 with usual SUS 304. And shape of chips is also compared.

• Structural Engineering and Mechanics
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• 제84권1호
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• pp.17-33
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• 2022

An experimental study is carried out to investigate the performance of the cutting tool regarding the insert wear, surface roughness, cutting forces, cutting power and material removal rate of three coated carbides GC2015 (TiCN-Al₂O₃-TiN), GC4215 (Al₂O₃-Ti(C,N)) and GC1015 (TiN) during the dry turning of AISI4140 steel. For this purpose, a Taguchi design (L₉) was adopted for the planning of the experiments, the effects of cutting parameters on the surface roughness (R_a), tangential cutting force (F_z), the cutting power (P_c) and the material removal rate (MRR) were studied using analysis of variance (ANOVA), the response surface methodology (RSM) was used for mathematical modeling, with which linear mathematical models were developed for forecasting of R_a, F_z, P_c and MRR as a function of cutting parameters (V_c, f, and a_p). Then, Multi-Objective Ant Lion Optimizer (MOALO) has been implemented for multi-objective optimization which allows manufacturers to enhance the production performances of the machined parts. Furthermore, in order to characterize and quantify the flank wear of the tested tools, some machining experiments were performed for 5 minutes of turning under a depth of 0.5 mm, a feed rate of 0.08 mm/rev, and a cutting speed of 350 m/min. The wear results led to a ratio (V_B-GC4215/V_B-GC2015) of 2.03 and (V_B-GC1015/V_B-GC2015) of 4.43, thus demonstrating the efficiency of the cutting insert GC2015. Moreover, SEM analysis shows the main wear mechanisms represented by abrasion, adhesion and chipping.

• 동력기계공학회지
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• 제20권5호
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• pp.5-13
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• 2016

This study is on wear damage of the material for a molding machine that be used at finally cutting of metal beam made in roll forming process of vehicle bump beam process line. SKD11 steel was used with the material for cutting mold jig. In the cutting mold jig, Ti diffusion heat treatment after vacuum heat treatment was carried out for upgrade of surface hardness and anti-wear. Also, the heat treatments by various methods were performed to compare the wear damage degree against above the existing heat treatment. Wear loss and friction coefficient were obtained from wear test. And, micro Vickers hardness values were compared with damaged parts or not of cutting mold jig. Micro Vickers hardness value appeared higher at the undamaged part by Ti diffusion heat treatment. The micro Vickers hardness well followed a two-parameter Weibull probability distribution.

• 한국정밀공학회지
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• 제6권4호
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• pp.94-102
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• 1989

The effect of plastic strain on the surface integrity of mild steel (SS 41) was studied. This paper shows that the recrystallization technique is adequate to evaluate the plastic strain in a machined surface experimentally. The relations between the plastic strain and the machining conditions are quantitatively evaluated by using the recrystallization technique. The obtained results are summarized as follows. 1. The surface integrity of steel is considerably influenced by the amount of surface region deformation produced by changes in cutting conditions. 2. The plastic strain in machined surface produced by changes of the cutting conditions is evaluated by the recyrstallization technique. 3. The plastic strain increases with the increase of depth of cut and the decrease of rake angle. 4. When the cutting force is high and the rake angle is small, the value of maximum true strain reaches to high. 5. The maximum true strain is related to the cutting energy, and the values increase with the increase of the unit shear and total engergy in constant depth with the increase of the energy values.