• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.4
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• pp.55-64
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• 2001

In this study, hemisphere and cylindrical shapes were machined for different tool paths and machining conditions with ball endmill cutters. Tool deflection, cutting forces and shape accuracy were measured according to the inclination position of the sculptured surface. As the decreasing of inclination position angle, the tool deflection was increased due to the decreased cutting speed when the cutting edge is approaching toward the center. Tool deflection when upward cutting is obtained less than that of downward cutting and down-milling in upward cutting showed the least tool deflection for the sculptured surface. Roundness values were found in least roundness error when down-milling in upward cutting. It is obtained the very little difference between 90。and 45。 of inclination position angle. The best surface roughness value was obtained in upward up-milling and showed different tendency with tool deflection and cutting force. For down-milling, the cutting resistance of the side wall direction is larger than that of feed direction. Therefore, this phenomenon which is received over cutting resistance can be caused of chatter.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.3
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• pp.57-65
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• 1997

In this study, a cutting force in the Ball-end milling process is calculated using Z-map. Z-map can describe any type of cutting area resulting from the previous cutting geometry and cutting condition. Cutting edge of a ball-end mill is divided into infinitesimal cutting edge elements and the position of the ele- ment is projected to the cutter plane normal to the Z axis. Also the cutting area in the cutter plane is obtained by using the Z-map. Comparing this projected position with cutting area, it can be determined whether it engages in the cutting. The cutting force can be calculated by numerical integration of cutting force acting on the engaged cutting edge elements. A series of experiments such as contouring and upward/downward ramp cutting was performed to verify the calculated cutting force.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.5-14
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• 2002

Hemisphere shapes were machined for different tool paths and machining conditions with ball endmill cutters. It was also found out how feedrate affect the precision of the machining and also tried to study the most suitable feedrate in specific cutting condition. Tool deflection, cutting forces and shape accuracy were measured according to the inclination position of the sculptured surface. As the decreasing of inclination position angle, the tool deflection was increased due to the decreased cutting speed when the cutting edge is approaching toward the center. Tool deflection when upward cutting IS obtained less than that of downward cutting and down-milling in upward cutting showed the least tool deflection for the sculptured surface. For down-milling, the cutting resistance of the side wall direction is larger than that of feed direction. It was found that the tool deflection is getting better as tool path is going to far from the center for convex surface.

• Journal of the Semiconductor & Display Technology
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• v.19 no.2
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• pp.37-44
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• 2020

In improving laser cutting of optical plastic films for mass production of optoelectronics display units, it is important to understand particle contamination over optical film surface due to fume particle generation and dispersion. This numerical study investigates the effects of downward and upward air flow motions on fume particle dispersion around laser cut line. The simulations employ random particle sampling of up to one million fume particles by probabilistic distributions of particle size, ejection velocity and angle, and fume particle dispersion and surface landing are predicted using Basset-Boussinesq-Oseen model of low Reynolds number flows. The numerical results show that downward air flow scatters fume particles of a certain size range farther away from laser cut line and aggravate surface contamination. However, upward air flow pushes fume particles of this size range back toward laser cut line or sucks them up with rising air motion, thus significantly alleviating surface contamination.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.3
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• pp.71-76
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• 2020

Various machining methods are being studied to improve the processing quality of the spherical R shape in press die. In this paper, we confirmed that changes in machining quality were associated with changes in cutting direction, path, and cutting angle, which are commonly used in the machining of molds. We obtained a surface roughness graph with each condition change in one specimen using an instrument that measured geometry and surface roughness simultaneously. The results of the study showed that the best surface roughness in the finish cut of the spherical surface was obtained using upward pick feed machining.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.4
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• pp.87-93
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• 2021

The mold industry is competitive, and mold should be processed under optimal conditions for efficient processing. However, the cutting conditions of the ball-end mill, which are a major factor in mold processing, are mostly set empirically, and considerable research is required for increasing the tool life and processing accuracy. In this study, a tool dynamometer and an eddy current sensor were used along with NI-DAQ, a data acquisition device, to obtain characteristic values of the cutting force and tool deformation during the ball end-mill machining of inclined surfaces at a machining center. The cutting force and tool deformation were measured in an experiment. It was found that the tool received the greatest cutting force at the end of the machining process, and the deformation of the tool increased rapidly. Furthermore, the cutting force tended to increase with the angle and number of rotations. The deformation increased rapidly during the machining of a 45° inclined surface.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.125-129
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• 1996

In this study, a method is proposed for the cutting force prediction of Ball-end milling process using Z-map is proposed. Any types of cutting area generated from previous cutting process can be expressed in z-map data. Cutting edge of a ball-end mill is divided into a set of finite cutting edges and the position of this edge is projected to the cross-section plane normal to the Z-axis. Comparing this projected position with Z-map data of cutting area and determining whether it is in the cutting region, total cutting force can be calculated by means of numerical integration. A series of experiments such as side cutting and upward/downard cutting was performet to verify the simulated cutting force.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.52-57
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• 1995

In order to suggest the proper cutting conditions of the CNC milling machining for the free-from surface, some experiments were carried out. In experiments, the influence of cutting conditions on the inclined spherical surface were examined by geometrical anlysis. In thos study, the roundness and cutting force were measured to know the effect of several cutting conditions on the machined surface and the cutting characteristics were carefully investigated. As the result, it was appeared that rigidder tool must be used and the cutting speed must be maintained constantlyfor more effective machining. It can be also known from the experiments that the improved machining surface obtained under about 80 degree, but coarse surface obtained over about 80 degree because of the existance of immproper shape of ball-end mill at the extreme portion.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.7
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• pp.112-119
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• 2001

In modern manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are being designed and produced to meet various sophisticated functional specifications. The cutting force is required not only for the design of machine and cutting tools, but also for the determination of the cutting conditions for the various machining operations. The ball-end mill is deflected by the cutting force and, the tool deflection is one of the main reasons of the machining errors on a free-form surface. Hence, The cutting force generated in the ball-end milling is the most important property of the machining. The purpose of this study is to find the characteristics of the cutting force in inclined plane and the resultant machining errors in the ball-end milling process. Although the depth of cut is constant in the inclined plane, the cutting force area varies due to the hemisphere of the ball-end mill.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.2 s.95
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• pp.123-129
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• 1999

Ball-end milling process is widely used in the die and mold manufacturing because of suitable one for the machining of free-form surface. During the process, the pencil cutting operation can be adopted before finish cut to eliminate overload in uncut area caused by large diameter of ball-end mill. The ball-end mill cutter for the pencil cutting is easily deflected by cutting force due to the long and thin shape, and the tool deflection in pencil cutting is one of the main reason of the machining errors in a free-form surface. The purpose of this study is to find the characteristics of deflected cutter trajectory by constructing measurement system with eddy-current sensor. It was found that the severe reduction of corner radius produced the overcut during the plane cutting. Up cutting method induced the overcut both plane and slope cutting, but down cutting one induced the undercut. From the experiments, down cutting with upward cutting path can generate the small undercut surface.