• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.41-47
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• 2012

Surface roughness is widely used as an index for processing degree of accuracy. Recently, regression analysis to predict the machining results are actively used to characterize a cutting operations. In the past, diamond machining had been used for ultra precision cutting operation, but now industrial diamond tools like PCD(Polycrystaline Diamond) has been widely used in ultraprecision machining of nonferrous metals. In this study, the authors focus on the effect of PCD tool property on the surface roughness of different types of aluminum alloy after cutting process by CNC operated lathe. Based on the regression analysis approach on a surface roughness data obtained by experiment, predictive analysis of surface roughness is effective to achieve better surface quality.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.5
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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.

• Journal of Mechanical Science and Technology
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• v.20 no.1
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• pp.85-93
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• 2006

The trend of miniaturization has been applied to the research of rockets to develop prototypes of micro rockets. In this paper, the development of a web-integrated prototyping system for three-dimensional micro rockets, and the results of combustion tests are discussed. The body of rocket was made of 6061 aluminum cylinder by lathe process. The three-dimensional micro nozzles were fabricated on the same aluminum by using micro endmills with ${\phi}100{\mu}m{sim}{\phi}500{\mu}m$ diameter. Two types of micro nozzle were fabricated and compared for performance. The total mass of the rockets was 7.32 g and that of propellant (gun powder) was 0.65 g. The thrust-to-weight ratio was between 1.58 and 1.74, and the flight test with 45 degree launch angle from the ground resulted in $46\;m{\sim}53\;m$ of horizontal flight distance. In addition, ABS housing for the micro machined rocket was fabricated using Fused Deposition Modeling (FDM). A web-based design, fabrication, and test system for micro nozzles was proposed to integrate the distributed hardware resources. Test data was sent to the designer via the same web server for the faster feedback to the rocket designer.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.69-74
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• 2012

Surface roughness is widely used as an index for processing degree of accuracy. Recently, regression analysis to predict the machining results are actively used to characterize a cutting operations. In the past, diamond machining had been used for ultra precision cutting operation, but now industrial diamond tools like PCD(Polycrystalline Diamond) have been widely used in ultraprecision machining of nonferrous metals. In this study, the authors focus on the effect of PCD tool property on the surface roughness of Al5083 aluminum alloy after cutting process by CNC operated lathe. Based on the regression analysis approach on a surface roughness data obtained by experiment, predictive analysis of surface roughness is effective to achieve better surface quality.

• Journal of the Korean Society of Industry Convergence
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• v.5 no.3
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• pp.201-208
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• 2002

The machine tool which operates by hand is replacing by CNC machine tool to improve the quality of the product and the productivity in modem mechanic industry. The precision of machine part is influenced greatly the surface roughness by cutting condition of machine tool. So this study was performed to examine the aluminium surface roughness of section according to change of strength rating, nose radius, cutting speed, using live center. The results of this study are as follows; 1. In the case of 56mm diameter of test piece(length is below triple of diameter), whether establish the live center or not, doesn't influence to the surface roughness, and it is possible to make product without the live center. 2. The average surface roughness of 42mm diameter(length is quadruple of diameter) is similar to the 56mm diameter in the cutting condition of nose radius 0.8mm and cutting speed 140mm/min, but there are increases and differences in other cutting conditions. 3. In the case of test piece length more 70m/min(140m/mm) and nose radius improved greatly using the live center. 4. In the case of test piece length is quintuple of diameter, the nose radius must choose big tool and increase the cutting speed in preference live center establishment availability to improve that is surface roughness. Conclusively, if aluminum test piece length is fewer than triple of diameter, can process without establishing live center. If aluminum test piece length is more than quintuple of diameter, cutting conditions to improve surface roughness are (1) cutting speed (2) nose radius (3) whether the live center uses or not.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.1
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• pp.63-68
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• 2018

At present, ultra-precision cutting technology has been studied in Korean research institutes, focusing on development of ultra-precision cutting tool technology and ultra-precision control engineering. However, the developed technologies are still far behind advanced countries. It focuses on metals including aluminum, copper and nickel, and nonmetals including plastics, silicone and germanium which require high precision while using a lathe. It is hard to implement high precision by grinding the aforementioned materials. To address the issue, the ultra-precision cutting technology has been developing by using ultra-precision machine tools very accurate and strong, and diamond tools highly abrasion-resistant. To address this issue, this study aims to conduct ultra-precision cutting by using ECTS (Error Compensation Tool Servo) to improve motion precision of elements and components, and compensate for motion errors in real time. An IR camera is used for analyzing cutting accuracy differences depending on the heat generated in diamond tools in cutting to examine the heat generated in cutting to study cutting accuracy depending on generated heat.

• International Journal of Precision Engineering and Manufacturing-Green Technology
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• v.5 no.5
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• pp.583-591
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• 2018

Tool-chip adhesion impacts on cutting performance significantly, especially in finish cutting process. To promote cutting tools' anti-adhesion property, the concave micro-grooves texture (MGT) and convex volcano-like texture (VLT) were fabricated separately on lathe tools' rake faces by laser surface texturing (LST). Various orientations of MGT and different area densities (9% and 48%) and regions (partial and full) of VLT were considered in textured patterns designing. The following orthogonal cutting experiments, machining of aluminum alloy 5038, analyzed tools' performances including cutting force, cutting stability, chip shape, rake face adhesion and abrasion. It indicated that under dry finish cutting conditions, MGT contributed to cutting stability and low cutting forces, meanwhile friction and normal force reduced by around 15% and 10%, respectively with a weak correlation to the grooves' orientation. High density VLT tools, on the other hand, presented an obvious anti-adhesion property. A $5{\mu}m$ reduction of crater wear's depth can be observed on textured rake faces after long length cutting and textured rake faces presented half size of BUE regions comparing to the flat tool, however, once the texture morphologies were filled or worn, the anti-adhesion effect could be invalid. The bearing ratio curve was employed to analysis tool-chip contact and durability of textured surfaces contributing to a better understanding of anti-adhesion and enhanced durability of the textured tools.