• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 추계학술대회 논문집
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• pp.270-273
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• 2002

This paper presents an effective cutting force model that enable us to predict the instantaneous cutting force in milling process from a knowledge of the work material properties and cutting conditions. The development of the model is based on the orthogonal machining theory with the effective rake angle which is defined in the plane containing the cutting velocity and chip flow vectors. Face milling tests are performed at different feeds and, a fairly good agreement is shown between the predicted cutting forces and test results.

• Journal of Computational Design and Engineering
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• 제2권4호
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• pp.233-247
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• 2015

In this paper, the cutting force calculation of ball-end mill processing was modeled mathematically. All derivations of cutting forces were directly based on the tangential, radial, and axial cutting force components. In the developed mathematical model of cutting forces, the relationship of average cutting force and the feed per flute was characterized as a linear function. The cutting force coefficient model was formulated by a function of average cutting force and other parameters such as cutter geometry, cutting conditions, and so on. An experimental method was proposed based on the stable milling condition to estimate the cutting force coefficients for ball-end mill. This method could be applied for each pair of tool and workpiece. The developed cutting force model has been successfully verified experimentally with very promising results.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2002년도 춘계학술대회 논문집
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• pp.308-313
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• 2002

In end milling process, the undeformed chip section area and cutting forces vary periodically with phase change of the tool. However, the real undeformed chip section area deviates from the geometrically ideal one owing to cutter runout and tool shape error. In this study, a method of estimating the real undeformed chip section area which reflects cutter runout and tool shape error was presented during down end-milling of Inconel 715 using measure cutting forces. Contrary to the up-end milling the value of radial specific cutting resistance, $K_r$, becomes larger as the helix angle increases from $30^{\circ}$ to $40^{\circ}$ and it shows almost same value at $50^{\circ}$ The value of tangential specific cutting resistance, $K_t$ becomes larger as the helix angle increases same as in up-end milling, the $KK_r$, and $K_t$ values show a tendency to decrease with increase of the modified chip section area and this tendency is distinct with helix angle $40^{\circ}$.

• 한국정밀공학회지
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• 제20권10호
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• pp.31-40
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• 2003

In this paper, optimal cutting condition to minimize the form error in side wall machining with a flat end mill is studied. Cutting forces and tool deflection are calculated considering surface shape generated by the previous cutting such as roughing. Using the form error prediction method from tool deflection, optimal cutting condition considering form accuracy is investigated. Also, the effects of tool teeth number, tool geometry and cutting conditions on form error are analyzed. The characteristics and the difference of generated surface shape in up and down milling are discussed and over-cut free condition in up milling is presented. Form error reduction method through successive up and down milling is also suggested. The effectiveness and usefulness of the presented method are verified from a series of cutting experiments under various cutting conditions. It is confirmed that form error prediction from tool deflection in side wall machining can be used in optimal cutting condition selection and real time surface error simulation for CAD/CAM systems. This study also contributes to cutting process optimization for the improvement of form accuracy especially in precision die and mold manufacturing.

• 한국기계가공학회지
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• 제15권4호
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• pp.40-45
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• 2016

Interrupted cutting has different cutting characteristics compared with continuous cutting. In interrupted cutting, the workpiece has a groove that regularly impacts the cutting tool and workpiece. Therefore, tool damage occurs rapidly, and this increases the cutting force and surface roughness. In this study, we performed interrupted cutting of carbon steel for machine structure (SM45C) using a coated carbide tool (TT7100). To predict the cutting force, we analyzed the experimental results with a regression analysis. The results were as follows: We confirmed that the factors affecting the principal force and radial force were cutting speed, depth of cut, and feed rate. From the multi-regression analysis, we deduced regression equations, and their coefficients of determination were 89.6, 89.27, and 28.27 for the principal, radial, and feed forces, respectively. This means that the regression equations were significant for the principal and radial forces but not for the feed force.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 추계학술대회 논문집
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• pp.37-42
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• 1997

Off-line feed rate scheduling is an advanced methodology to automatically determine optimum feed rates for the optimization of NC code. However, the present feed rate scheduling systems have lim~tations to generate the optimized NC codes because they use the material removal rate or non-generalized cutting force model. In this paper, a feed rate scheduling system based on an improved cutting force model that can predrct cutting forces exactly in general machining was presented. Original blocks of NC code were divided to small ones with the modified feed rates to adjust the peak value of cutting forces to a constant vale. The characteristic of acceleration and deceleration for a given machrne tool was considered when off-line feed rate scheduhng was performed. Software for the NC code optimization was developed and applied to pocket machining simulation.

• Steel and Composite Structures
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• 제19권6호
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• pp.1467-1481
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• 2015

This paper presents a contribution to improving an analytical thermo-mechanical modeling of Oxley's machining theory of orthogonal metals cutting, which objective is the prediction of the cutting forces, the average stresses, temperatures and the geometric quantities in primary and secondary shear zones. These parameters will then be injected into the developed model of Karas et al. (2013) to predict temperature distributions at the tool-chip-workpiece interface. The amendment to Oxley's modified model is the reduction of the estimation of time-related variables cutting process such as cutting forces, temperatures in primary and secondary shear zones and geometric variables by the introduction the constitutive equation of Johnson-Cook model. The model-modified validation is performed by comparing some experimental results with the predictions for machining of 0.38% carbon steel.

• 한국정밀공학회지
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• 제12권3호
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• pp.92-100
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• 1995

This experimental study is mainly investigated on the mean cutting forces and AE(acoustic emission) parameters in order to detect and estimate the tool failure in the pachinig of SUS304 by face milling Mean cutting forces and AE parameters can detect the tool failure in face milling. Effective detection parameters are AE RMS, AE energy, AE count, AE duration, and z-direction mean cutting force. From the analysis of cutting tool failure detection, the tool failure of face milling is caused by sudden increasing of the cutting force.

• 대한기계학회논문집
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• 제17권6호
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• pp.1456-1464
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• 1993

본 논문에서는 다이아몬드 공구를 사용한 절삭과정에 대하여 절삭력 관계식을 제안하고, 이를 실제 천연 다이아몬드 공구를 이용하여 알루미늄 합금을 절삭하는 실험해석을 통하여 절삭력을 예측하는 모델을 세우고자 한다.

• 터널과지하공간
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• 제32권4호
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• pp.243-253
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• 2022

본 연구에서는 회전식 절삭시험기를 활용하여 TBE (Tunnel Boring Extender)의 굴착효율을 평가하였다. 회전식절삭시험에서 TBE에 의한 굴착과정을 모사하기 위하여 중앙부가 선행 굴착되어 있는 중공형의 암석모사시험체를 모르타르를 이용하여 제작하였다. 회전식 절삭시험기에 설치된 언더커팅 디스크(undercutting disc cutter, UDC)를 이용하여 나선궤적을 따라 암석을 절삭함으로써 TBE에 의한 굴착과정을 모사하였으며, 언더커팅 디스크의 절삭조건을 변화시켜가며 절삭조건들이 커터작용력 및 비에너지에 미치는 영향을 살펴보았다. 시험결과로부터 UDC의 커터작용력은 반경압입깊이와 수직압입깊이가 증가함에 따라 선형적으로 증가하는 경향을 확인할 수 있었으며, 세 방향의 작용력 중 수직력의 비중이 매우 크게 나타났다. 반면 비에너지는 반경방향과 수직방향 압입깊이에 따라 지속적으로 감소하는 경향을 나타내었고, 특히 두 압입깊이의 비에 따라 비에너지가 최소화되는 지점이 나타날 것으로 판단되었다.