• Journal of the Korean Society for Precision Engineering
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• v.17 no.7
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• pp.132-140
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• 2000

Plasma arc cutting is one of the most widely used processes in metal cutting fields and is a process that produces parted metal plates by cutting them with an arc plasma established between the electrode tip and the plate(workpiece). When the tip-to-workpiece distance varies during cutting, the cut quality, for example the kerf width, is deteriorated by the change of plasma arc. The variations of tip-to-workpiece distance are due to the different factors such as inaccuracies in setting the torch or workpiece, thermal distortions during cutting, and uneven surface of workpiece. The control to keep the tip-to-workpiece distance constant is thus indispensable to improve the flexibility of automatic plasma arc cutting system applications. In this study, an arc sensor which utilizes the electrical signal obtained from the plasma arc itself was developed. The arc sensor has an advantage that no particular sensing device is necessary and real-time sensing of the tip-to-workpiece distance is possible directly under the plasma arc. The relationship between plasma arc voltage and tip-to-workpiece distance was determined through the repeated experimental results. The model was used for developing an automatic tip-to-workpiece distance control system of plasma arc cutting. It could be shown that the proposed system has a successful capability of tip-to-workpiece distance control.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.1
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• pp.11-18
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• 2011

A worm screw is widely used in a geared motor unit for motion conversion from rotation to linear. For mass production of a high quality worm, the current rolling process is substituted with the milling process. Since the milling process enables the integration of all operations of worm manufacturing on a CNC(Computer Numerical Control) lathe, productivity can be remarkably improved. In this study, the tooling system for side milling on a CNC lathe to improve machinability is developed. However, the cutting tool-workpiece interference is important factors to be considered for producing high quality worms. For adaptability of various worms machining, the tool-workpiece interference simulation system based on a tool-tip trajectory model is developed. The developed simulation system is verified through several kinds of worms and experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.12
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• pp.47-54
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• 2009

A worm screw is widely used in a geared motor unit for motion conversion from rotation to linear. For mass production of a high quality worm, the current rolling process is substituted with the milling process. Since the milling process enables the integration of all operations of worm manufacturing on a CNC(Computer Numerical Control) lathe, productivity can be remarkably improved. In this study, the tooling system for planetary milling on a CNC lathe to improve machinability is developed. However, the cutting tool-workpiece interference is important factors to be considered for producing high quality worms. For adaptability of various worms machining, the tool-workpiece interference simulation system based on a tool-tip trajectory model is developed. The developed simulation system is verified through several kinds of worms and experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.4 no.4
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• pp.84-92
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• 1987

To investigate the influence of the cutting pressure on the laser cutting quality, an expermental facility was constructed which can measure the cutting pressure distribution for various cutting conditions. Flow visualization was performed using the Schlieren photography and the pressure acting on the workpiece surface was measured, corresponding to the important process variables such as the kind of assist gas, nozzle pressure, distance between the nozzle exit and the workpiece surface, and the presence of the secondary nozzle. The cutting pressure acting on the workpiece was largely influenced by the nozzle pressure and nozzle-workpiece distance. The secondary nozzle which is used to raise the effective working pressure had its obvious role only when the angle between it and the main nozzle was small and when the distance between the nozzle exit and the workpiece surface was large.

• Journal of the Korean Society for Precision Engineering
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• v.5 no.1
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• pp.63-70
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• 1988

Laser cutting system uses a gas jet to remove the molten or varpozed material from the workpiece. The quality of the laser cut can be strongly influenced by the gas flow charac- teristics formed through the nozzle. Laser cutting experiments were carried out for SS41 and SUS 304 to investigate the relationship between cut quality and cutting pressure. The cutting speed, nozzle pressure and nozzle to workpiece distance were also considered. The cut specimens were inspected by various manners such as dross observation, surface roughness test and kerf width measurement. Based on the data of pressure measurement on workpiece and the results of cut surface inspection, the influence of the considered cutting conditions on cut quality could be evaluated. The results of this study will be valuable in planning the optimal laser cutting process and in designing the laser cutting nozzle.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.2
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• pp.940-946
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• 2015

The turning clearance angle changes the machining characteristics. In this study, three workpiece materials, machine structural carbon steel, chrome-molybdenum steel and stainless steel, were examined. The experiments revealed how the features of selected materials changed when they were processed with machining operation. To find the surface roughness of workpiece materials, the workpiece materials, which have a higher tensile strength, showed a much better surface roughness in the surface roughness tester. Moreover, the process feed rate was compared between 0.07 mm/rev and 0.10 mm/rev. When the process feed rate was 0.07 mm/rev, the surface roughness has superior results without reference to the quality of the materials. According to this research on the turning clearance angle, the best roughness value was observed when the quality of the materials were $0.9^{\circ}$, whereas the worst roughness was observed when quality of the materials was $0.3^{\circ}$.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.64-70
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• 2001

This work deals with the electrical conductivity of dielectric and cobalt percentage on output parameters such as metal removal rate and surface roughness value of sintered carbides cut by wire-electrical discharge machining (W-EDM). To obtain a precise workpiece with good quality, some extra repetitive finish cuts along the rough cutting contour are necessary. Experimental results show that increases of cobalt amount in carbides affects the metal removal rate and worsens the surface quality as a greater quantity of solidified metal deposits on the eroded surface. Lower electrical conductivity of the dielectric results in a higher metal removal rate as the gap between wire electrode and workpiece reduced. Especially, the surface characteristics of rough-cut workpiece and wire electrode were analyzed too. To obtain a good surface equality without cracks, 4 finish-cuts were necessary by reducing the electrical energy and the offset value.

• Journal of Mechanical Science and Technology
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• v.15 no.12
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• pp.1676-1682
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• 2001

This work deals with the electrical conductivity of dielectric and cobalts percentage on output parameters such as metal removal rate and surface roughness value of sintered carbides cut by wire-electrical discharge machining (WEDM). To obtain a precise workpiece with good quality, some extra repetitive finish cuts along the rough cutting contour are necessary, Experimental results show that increases of cobalt amount in carbides affects the metal removal rate and worsens the surface quality as a greater quantity of solidified metal deposits on the eroded surface. Lower electrical conductivity of the dielectric results in a higher metal removal rare as the gap between wire electrode and workpiece reduced. Especially, the surface characteristics of rough-cut workpiece and wire electrode were analyzed too. To obtain a good surface equality without crack, 4 finish-cuts were necessary reducing fille electrical energy and the offset value.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.6
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• pp.590-597
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• 2009

The final quality of the workpiece is affected by the grinding process that has been conducted in final manufacturing stage. However the quality-satisfaction of ground workpiece depends on the skill of an expert in this process. Therefore, the process models of grinding have been developed to predict the states according to grinding process. In this paper, in order to find the optimized grinding condition to reduce the manufacturing expense and to meet requirements of ground workpiece optimization algorithm using E.S.(Evolutionary Strategy) is proposed. The proposed algorithm has been employed to find the optimal grinding and dressing condition using the grinding process models and nonlinear grinding constraints. The optimized results also presents the guide line of grinding process. The effectiveness of the proposed algorithm is verified through the experimental results.

• Journal of the Korean Society of Safety
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• v.11 no.3
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• pp.10-19
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• 1996

Grinding temperature and thermal deformation(dimensional error) are studied theoretically and experimentally. The propose of this research is clarified loading phenomena and residual stress In order to guide nozzle's efficiency. The main results to be obtained are as follows ; 1) When grinding condition Is high efficient grinding, FEM program is developed about grinding heat and dimensional error. 2) Thermal deformation depend on temperature distribution is in good agreement with experimental results in case of little grinding energy flux but is comparatively in good agreement with in case of large (3.5$\times$10$^{6}$ J/m). 3) In terms of high efficient grinding at field(table speed 4m/min), grinding fluid (dilution 5/100) obtained a good workpiece quality and decreased a grinding temperature. 4) A surface roughness, dimensional error, residual stress and loading phenomena with guide nozzle are decreased and these results obtained a good workpiece quality.