• Journal of the Korean Society for Precision Engineering
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• v.15 no.3
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• pp.75-81
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• 1998

In the machining process, variation in cutting forces results in relative displacements between the tool and the workpiece leading to tool vibration. Also there is a demand to change the depth of cut very frequently. One solution for the both cases is to develop a system which has the ability to reposition a cutting tool to a very small level, i.e., micron. This paper presents the development of a micropositioner using a magnetostrictive material. The developed micropositioner is implemented to a lathe and subjected to various tests. The results show that the micropositioner with a magnetostrictive actuator has good potential for machining application.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.11
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• pp.171-178
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• 2004

This paper presents vibration characteristics of a wire cut discharge machine in which an electro-rheological brake actuator is used to control the wire tension. The ER brake actuator has several advantages including design simplicity, fast response time and real-time controllability. On the basis of the tension level required in the machine an appropriate size of the ER brake actuator is devised. The ER brake actuator is then incorporated with the machine and the field-dependent wire tension is experimentally evaluated. The straightness of the workpiece is also empirically investigated by changing the intensity of the electric field.

• Journal of the Korean Society for Precision Engineering
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• v.11 no.1
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• pp.219-229
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• 1994

This paper describes an expert system on the cylindrical grinding operations in order to establish the optimum grinding conditions, which satisfy the maximum removal rates, considering the several constraints of grinding power, workpiece burn, chatter vibration and surface roughness. Specialized knowledge of the grinding operations are acquired from the actual operation database. Coefficientis in the experimental equations are obtaines through the fuzzy regression model based on the fuzzy set theory, and are stored in the actual operation database. The developed system is capable of determining the optimum grinding conditions taking into account some problems, and practical examples of implementaion are described.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.8
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• pp.1951-1962
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• 1993

The creation process of a typical machined surface is treated here as a dynamic system. An investigation is carried out to establish a relationship between the characteristics of cutting force fluctuations that cause vibration response of the tool-workpiece system and the formation of surface in face cutting by sintered carbide cutting tool. Cutting force is measured and analyzed in frequency domain. The power spectral densities of cutting force give a useful information in surface generation and it can be used to find out the control factor of surface roughness. The terms, PSD ratio & Normalized spindle frequency PSD, are defined and when the value of power in spindle frequency is absolutely little but relatively large, it is obtained high accuracy surface roughness. The aim of this research is to find surface profile by measured and analyzed cutting force signals. The simulation of surface generation gives the comprechension of its mechanism and help to predict and control the surface quality. In this study, it is suggested what informations about surface generation can be acquired from the cuttuing force signal and an way of generating a better surface.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.10
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• pp.139-145
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• 1996

The machining accuracy and performance is largely influenced by the static, dynamic and thermal characteristics of spindle systems in machine tools, because the spindle system is a intermedium for cutting force from tool and machine powef from motor. Large cutting force and power are transmitted by bearing with a point or line contact. So, the spindle system is the static and dynamic weakest point in machine structure. For improvement of static stiffness of spindle system can be changed design parameters, such as diameter of spindle, stiffness of bearing and bearing span. But for dynamic stiffness, the change of the design parameters are not useful. In this paper, the combined bearing arrangement is suggested for high damping spindle system. The combined bearing arrangement is composed of tandem double back to back arrangement type ball bearins and a high damping hydrostatic bearing. The variation of static deflection and amplitude in first natural frequency is evaluated with the location of hydrostatic bearing between front and rear ball bearing. The optimized location of hydrostatic bearing for high static and dynamic stiffness is determined rapidly and exactly using the mode shape and transfer function of spindle. The calculation of damping effect on vibration by unbalance of grinding wheel and pulley in optimized spindle system is carried out to verify the validity of the combined bearing arrangement. Finally, the simulation of grinding process show that the surface roughness of workpiece with high damping spindle system is 60% better than with ball bearing spindle system.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.6 no.1
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• pp.43-49
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• 2007

Multi-function and miniaturization of the medical equipment and tele-communication systems need small and high precision machined parts. For the economic machining of the small size workpiece it should be machined by small and high precision machine tools with high speed machining. The belt type driving system in turning lathe has a limitation of spindle speeds because of the vibrations from driving mechanism, built-in type of driving mechanism is used to reduce the vibration. However, the main spindle of the built-in motor is connected directly to the motor, so the heat generation of the motor and bearing makes bad influence of the accuracy of machine tools. In this study, the analysis of heat generation from motor and bearings supporting main spindle and experiment were carried out. The results of theoretical simulation of temperature and deformation of the main spindle are good agreement with those of measured.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.960-963
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• 2001

An internal finishing process by the application of magnetic abrasive machining has been developed as a new technology to obtain a fine inner surface of pipe. In this paper, another method of magnetic abrasive machining in which the N and S magnetic poles are vibrated and a workpiece is rotated only is tried in a non-ferromagnetic pipe(SUS304), and its finishing characteristics is experimental results, it is found that the vibration effects of magnetic poles on the finishing characteristics are large in internal finishing.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.5
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• pp.108-114
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• 2007

A new cutting force estimating approach and machining state monitoring examples are presented which uses a cylindrical displacement sensor built into the spindle. To identify the tool-spindle system dynamics with frequency up to 2 kHz, a home-built electro-magnetic exciter is used. The result is used to build an algorithm to extract the dynamic cutting force signal from the spindle error motion; because the built-in spindle sensor signal contains both spindle-tool dynamics and tool-workpiece interactions. This sensor is very sensitive and can measure broadband signal without affecting the system dynamics. The main characteristic is that it is designed so that the measurement is irrelevant to the geometric errors by covering the entire circumferential area between the target and sensor. It is also very simple to be installed. Usually the spindle front cover part is copied and replaced with a new one with this sensor added. It gives valuable information about the operating condition of the spindle at any time. It can be used to monitor cutting force and chatter vibration, to predict roughness and to compensate the form error by overriding spindle speed or feed rate. This approach is particularly useful in monitoring a high speed machining process.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.8
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• pp.1287-1294
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• 2003

The wear process of end mill is so complicated process that a more reliable technique is required for the monitoring and controlling the tool life and its performance. This research presents a new tool wear monitoring method based on the sound signal generated on the machining. The experiment carried out continuous-side-milling for 4 cases using the high-speed-steel end mill under wet condition. The sound pressure was measured at 0.5m from the cutting zone by a dynamic microphone, and was analyzed at frequency domain. As the cutter impacts the workpiece surface, a situation of farced vibration arises in which the dominant forcing frequency is equal to the tooth passing frequency of the cutter. The tooth passing frequency appears as a harmonics form, and end mill flank wear is related with the first harmonic. It is possible to detect end . mill flank wear. This paper proposed the new method of the end mill wear detection.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.23-29
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• 2016

Rotary machine is major equipment in industry. The rotary machine is applied for a machine tool, ship, vehicle, power plant, and so on. But a spindle fault increase product's expense and decrease quality of a workpiece in machine tool. A turbine in power plant is directly connected to human safety. National crisis could be happened by stopping of rotary machine in nuclear plant. Therefore, it is very important to know rotary machine condition in industry field. This study mentioned fault diagnosis algorithm with statistical parameter and empirical mode decomposition. Vibration locations can be found by analyze kurtosis of data from triaxial axis. Support vector of data determine threshold using hyperplane with fault location. Empirical mode decomposition is used to find fault caused by intrinsic mode. This paper suggested algorithm to find direction and causes from generated fault.