• 대한기계학회:학술대회논문집
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• 대한기계학회 2003년도 춘계학술대회
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• pp.968-973
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• 2003

As environmental restrictions have continuously become more strict, it has emphasized development of environment-friendly technologies. In cutting technology, it has been well recognized that cutting fluids might have undesirable effects on worker's health and working environment and, hence, recently there have been numerous attempts to minimize harmful effects of cutting fluids on environments. To minimize the use of cutting fluids in machining, conventional cutting fluids have been replaced with the technologies of pressurized cold air and minimum quantity lubrication(MQL). Compared with milling, turning is a continuous cutting process, where tools are continuously heated up and lack of lubricity could lead to tool wear and deteriorated surface roughness. In this study, it has been investigated how tool wear and surface roughness could be affected by cutting conditions, supply and cooling methods. The experimental results show that MQL technology is able to minimize harmful effects of conventional cutting fluids.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 춘계학술대회 논문집
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• pp.49-52
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• 1996

The control of diamond turning is usually achieved through a laser-interferometer feedback of slide position. The limitation of this control scheme is that the feedback signal does not account for additional dynamics of the tool post and the material removal process. If the tool post is rigid and the material removal process is relatively static, then such a non-collocated position feedback control scheme may surfice. However, as the accuracy requirement gets tighter and desired surface contours become more complex, the need for a direct tool-tip sensing becomes inevitable. The physical constraints of the machining processprohibit any reasonable implementation of a tool-tip motion measurement. It is proposed that the measured force normalto the face of the workpice can be filterd through an appropriate admittance transfer function to result in the estimated depth of cut. This can be compared to the desired depth of cut to generate the adjustment cotnrol action in addition to position feedback control. In this work, the design methodology on the admittance model-based control with a conventional controller is presented. Based on the empirical data of the cutting dynamics, simulation results are shown.

• 한국공작기계학회논문집
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• 제10권1호
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• pp.1-9
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• 2001

The development of flexible automation in the manufacturing industry is concerned with production activities performed by unmanned machining system A major topic relevant to metal-cutting operations is monitoring toll wear, which affects process efficiency and product quality, and implementing automatic toll replacements. In this paper, the measurement of the cutting force components has been found to provide a method for an in-process detection of tool wear. The static com-ponents of cutting force have been used to detect flank wear. To eliminate the influence of variations in cutting conditions, tools, and workpiece materials, the force modeling is performed for various cutting conditions. The normalized force dis-parities are defined in this paper, and the relationships between normalized disparity and flank were are established. Final-ly, artificial neural network is used to learn these relationships and detect tool wear. According to proposed method, the static force components could provide the effective means to detect flank wear for varying cutting conditions in turning operation.

• 한국생산제조학회지
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• 제21권5호
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• pp.824-829
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• 2012

The purpose of this study is to evaluate the proposed jig for turning process of large-scale aluminum tube of D500mm through Finite Element Analysis (FEA). Also, a machining evaluation is conducted with general heat-treated and cryogenic heat-treated tubes. Dimensions of the specimens are determined to be suitable for collet appearance. The characteristics of equivalent stress and strain according to the expansion of the collet are evaluated by FEA. The aluminum tubes which are heat-treated by T4/T6 condition and cryogenic condition are machined by using a large-scale lathe machine and the roundness of machined tube is evaluated by using a 3D measuring machine. Through the results of this study, effects of each heat treatment and residual stress on the roundness are established.

• 한국정밀공학회지
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• 제12권10호
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• pp.5-17
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• 1995

기계가공(Machining)중에서 가장 기본적인 것이 선삭(Turning)작업이며, 이 가공은 선반(Lathe)에 의해서 행하여지고 있는 것은 다 아는 사실이다. 공작기계의 발달과 금속 절삭 원리(Principles of metal cutting)는 선반을 중심으로 약 일세기동안 꾸준히 발전해 오고 있으며, 수없이 쏟아져 나온 연구논문들의 대부분이 선반에 의한 가공과 그 공작기계에 의해서 이루어졌으며 앞으로도 계속 보통선반, CNC선반의 토대 위에서 이루어지리라고 보고 있다. 공작기계 중에서 CNC 선반의 발달 과정을 요약해보면 1960년대의 대량 생산시대에는 Programmable control 방식의 자동 터렛트(Turret) 선반이 개발되어 생산 공정이 비교적 간단한 양산 가공기로서 환영을 받게 되었다. 1970년대에 들어서면서 다품종소량생산이 중요시되었고, 그때 NC 선반시대가 시작되었다고 볼 수 있다. 현 싯점에서 볼 때 이것은 중품종중량생산 이라고 말할 수 있으며, Turret 선반의 NC화 즉, Multi-tool에 의한 선반의 복합가공이 가능해졌지만 Tooling에 문제가 발생하였다. 1980년에 들어서 각종 MC 들이 광범위하게 발달, 보급되는 경향에 따라서 NC 선반도 고능률화의 일환으로 고속화와 더불어 회전공구인 End mill. Drill. Tap 등의 복합가공이 가능한 복합선반이 차례로 개발되었고 선삭공구와 회전공구등의 자동공구교환(Automatic Tool. Changing. ATC)이 가능해지고 Y축 보정(Co-mpensation)기구를 부착한 대형 Turning center가 개발되어 보급되게 되었다.

• 대한기계학회논문집A
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• 제33권7호
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• pp.621-628
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• 2009

Nickel-phosphorus alloys are attractive materials for diamond turning applications such as fabrication of large optics and other high precision parts. It is also well-known that the higher phosphorus content of the alloys minimizes the diamond tool wear. Due to the weakness of electoless nickel plating that the phosphorus contents is limited to 13-14% (wgt), increased attention has been paid at electro-nickel plating which enables the alloys with 15-16% phosphorus. In this study, experiments were carried out to observe the wear characteristic of single crystal diamond tools in micro-grooving of electro-nickel plated drums. The experiments shows that long distance (50km) machining of micro-grooving on electro-nickel plated drum is possible with a single crystal diamond tool without any significant tool wear and defective machined surface.

• 한국주조공학회지
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• 제42권3호
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• pp.191-197
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• 2022

This study aims to improve the machinability of gray cast irons in high speed cutting by using nonmetallic inclusions. In this research, small quantities of AL and Mg were added to conventional gray cast irons without influencing their mechanical characteristics and castability to investigate the effects of these nonmetallic inclusions in the gray cast irons on tool wear in high speed cutting. During the high speed turning of gray cast iron containing Al and Mg using a cermet tool, protective layers consisting of Al, Mg, Si, Mn, S and O were detected on the flank face and rake face of the tool, and flank and crater wear were significantly reduced compared to the turning of conventional gray cast iron and gray cast iron added with Al. The effect of inclusions on tool wear increased with increasing cutting speed, and flank and crater wear was the smallest at the cutting speed of 700m/min. Moreover, in face milling, the addition of Al and Mg drastically decreased the wear rate, and wear hardly progressed even in prolonged cutting length after initial wear. The amount of adhesion on tool faces increased as the cutting speed increased. This increase in cutting speed resulted in the formation of a thick protective layer and the reduction of tool wear. Furthermore, the addition of small amounts of Al and Mg prevented thermal cracks in the face milling of gray cast irons.

• Design & Manufacturing
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• 제16권3호
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• pp.16-21
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• 2022

In order to reduce the weight of parts and materials for the development of high-efficiency engines in accordance with the strengthening of automobile fuel efficiency regulations, the existing casting material is changed to a iron plate material, and plastic processing and turning operations are performed to lighten the weight and reduce the manufacturing cost. Among the pulley components applied to the damper pulley, the HUB product was manufactured by plastic machining instead of the existing casting process, and the inspection standardized for automating the inner diameter and parallelism measurement of the turning result of the new hub part with improved quality, and the inspection system for this Development of design and operation software to automate the inspection of the inner diameter and parallelism of the hub was described. The representative specifications of the development equipment are a hub inner diameter 22mm inspection system, a three-point inspection system with a parallelism of 0.15mm on the top.

• Journal of Mechanical Science and Technology
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• 제18권5호
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• pp.770-779
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• 2004

This paper describes the micro cutting of wear resistant tungsten carbides using PCD (Poly-Crystalline Diamond) cutting tools in performance with SEM (Scanning Electron Microscope) direct observation method. Turning experiments were also carried out on this alloy (V50) using a PCD cutting tool. One of the purposes of this study is to describe clearly the cutting mechanism of tungsten carbides and the behavior of WC particles in the deformation zone in orthogonal micro cutting. Other purposes are to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, machined surface and tool wear rates by the outer turning of this alloy carried out using the PCD cutting tool during these various cutting conditions. A summary of the results are as follows: (1) From the SEM direct observation in cutting the tungsten carbide, WC particles are broken and come into contact with the tool edge directly. This causes tool wear in which portions scrape the tool in a strong manner. (2) There are two chip formation types. One is where the shear angle is comparatively small and the crack of the shear plane becomes wide. The other is a type where the shear angle is above 45 degrees and the crack of the shear plane does not widen. These differences are caused by the stress condition which gives rise to the friction at the shear plane. (3) The thrust cutting forces tend to increase more rapidly than the principal forces, as the depth of cut and the cutting speed are increased preferably in the orthogonal micro cutting. (4) The tool wear on the flank face was larger than that on the rake face in the orthogonal micro cutting. (5) Three components of cutting force in the conventional turning experiments were different in balance from ordinary cutting such as the cutting of steel or cast iron. Those expressed a large value of thrust force, principal force, and feed force. (6) From the viewpoint of high efficient cutting found within this research, a proper cutting speed was 15 m/min and a proper feed rate was 0.1 mm/rev. In this case, it was found that the tool life of a PCD tool was limited to a distance of approximately 230 m. (7) When the depth of cut was 0.1 mm, there was no influence of the feed rate on the feed force. The feed force tended to decrease, as the cutting distance was long, because the tool was worn and the tool edge retreated. (8) The main tool wear of a PCD tool in this research was due to the flank wear within the maximum value of $V_{max}$ being about 260 $\mu\textrm{m}$.

• 한국기계가공학회지
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• 제19권6호
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• pp.73-79
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• 2020

Although engineering plastics that are light-weight and have excellent mechanical performance have been widely applied in various industries in place of steel structures to reduce the burden of cost and time, there have been few studies related to their surface roughness. This study aims to evaluate the optimal effects of feed rate, cutting speed, and depth of cut as cutting parameters as well as nose angle on the surface characteristics of MC nylon in CNC lathe machining. To determine the best conditions under different nose radii, the experiments were performed based on the Taguchi L9(34) orthogonal array method, in which the resulting data was analyzed using the S/N ratio and ANOVA. Results indicate that the most significant contribution was feed rate followed by nose angle and cutting speed, whereas the depth of cut did not influence the performance. This study demonstrates that the suggested method for improving the surface finishing of MC nylon is efficient compared with results obtained from experimentation and prediction.