• Journal of the Korean Society for Precision Engineering
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• v.20 no.9
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• pp.55-62
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• 2003

This paper investigates the micro-cutting of cemented carbides using PCD (polycrystalline diamond) and PCBN (polycrystalline cubic boron nitride) cutting tools are performed with SEM direct observation method. The purpose of this study is to make clear the cutting mechanism of cemented carbides and the fracture of WC particles at the plastic deformation zone in orthogonal micro-cutting. And also to achieve systematic understanding, the effect of machining parameter on chip formation and machined surface was studied, including cutting speed, depth of cut and various tool rake angle. Summary of the results are shown below. (1) Three type of chip formation process have been proposed by the results of the direct observation in orthogonal micro-cutting of cemented carbide materials. (2) From the whole observation of chip formation, primary WC particles are crushed and/or fine grained in the shearing deformation zone. A part of them are observed to collide directly with a cutting edge of tool by following the micro-cutting. (3) Surface finish, surface morphology and surface integrity is good to obtain by cutting with PCD cutting tool compared with PCBN. (4) The machined surface has the best quality near the low cutting speed of 10${\mu}m$/sec with a cutting depth of 10 ${\mu}m$ using 0$^\circ$ rake angle and 3$^\circ$ flank angle in this condition, but it was found that excessively low speed, for example the extent of 1 ${\mu}m$/sec, is not good enough to select for various reason.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.1
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• pp.85-91
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• 2013

The machinability of wear-resistible tungsten carbides and the tool wear behavior in machining of V30 and V50 tungsten carbides using PCD (Poly Crystalline Diamond) cutting tool was investigated to understand machining characteristics. This material is one of the difficult-to-cut materials in present, but their usage has been already broadened to every commercial applications such as mining tools, and impact resistant tools etc. Summary of the results are as follows. (1) Tool wear progression of PCD tools in turning of wear-resistible tungsten carbides were observed specially fast in primary cutting distance within 10m. (2) Three components of cutting resistance in this research were different in balance from the ordinary cutting such as that cutting of steel or cast iron. Those were expressed large value by order of thrust force, principal force, feed force. (3) If presume from viewpoint of high efficient cutting within this research, a proper cutting speed was 15m/min and a proper feed rate was 0.1mm/rev. In this case, it was found that the tool life of PCD tool was cutting distance until 230m approximately. (4) In cutting of wear-resistible tungsten carbides such as V30 and V50, it was recognized that the tool wear rate of V30 was very fast as compared with V50. (5) When the depth of cut was 0.1mm, there was no influence of the feed rate on the feed force. And the feed force tended to decrease as the cutting distance was long, because the tool was worn and the tool edge retreated. (6) It was observed that the tungsten carbides were adhered to the flank.

• Journal of the Korean Society for Heat Treatment
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• v.6 no.1
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• pp.1-8
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• 1993

In this paper, the surface roughness influenced by Sm45C hardness in high frequency induction hardening and mechanical characteristics for the changed Hv 598 part and the unchanged hardness Hv 223 part by use of cermet and ceramic cutting tools was experimentally examined. Finally, we could be had some important results by processing surface roughness on cutting conditions such as cutting speed, feed rate, depth of cut and changes of tool nose radius. The results are summarized as follows. 1. In case of the same cutting condition, the hardness of workpiece was high and acquired the best processing surface roughness when the radius of the tool nose had 0.8 mm and feed rate was 0.04 mm/rev. 2. In case of the hardness of workpiece, though the cutting speed didn't have an effect on processing surface roughness, the less feed rate and the more processing surface roughness improved. On the other hand, the low inside the hardness of workpiece, the more cutting speed and the more feed rate increase, the processing surface of roughness improved. 3. Regardless of the hardness of workpiece, the change of the cutting depth didn't have great effect on the surface roughness. 4. On cutting the high surface hardness part with cutting tools of cermet and ceramic, it can be acquired the higher processing surface roughness because it hadn't been taken effect on cutting speed, In case of the cutting process of the low inside hardness part the two cutting tools have acquired the similar processing surface roughness.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.321-326
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• 2001

In the present study, $Si_3N_4-SiC$ ceramic composites that contained up to 20 wt% of dispersed SiC particles were fabricated via hot-pressing with an oxynitride glass. The microstructure, the mechanical properties, and the cutting performance of resulting ceramic composites were investigated. By fixing the composition as $Si_3N_4-20$ wt% SiC, the effect of sintering time on the microstructure, the mechanical properties, and the cutting performance were also investigated. For machining of gray cast i개n, the tool life increases with increasing the amount of SiC content in the composites; The tool life also increased with increasing the sintering time. The tool life of the home-made cutting tools was very close to that of commercial $Si_3N_4$ cutting tool. The superior cutting performance of $Si_3N_4-SiC$ ceramic cutting tools suggests the possibility to be a new ceramic tool material.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.1
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• pp.78-83
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• 1996

This paper presents the characteristics of surface roughness and cutting force in ultraprecision cutting of aluminium alloy using natural diamond tools whose edge radii are smaller than those of tools made of other materials. The feed rate and depth of engagement were set to be a micrometer order. After measuring the surface roughness of machined surface and cutting force for each cutting condition, the relations between the surface quality and its condition were investigated qualitatively. If the feed rate was under a certain limit, the machined surface quality was deteriorated unexpectedly. This is supposed to have happened due to vibration leading its condition to abnormal one. In a certain situation the machined surface roughness by a natural diamond tool was inferior to that made by a carbide tool whose cutting edge radius is larger. This is supposed to be caused by not normal machining but burnishing effect.

• Journal of the Korean Ceramic Society
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• v.31 no.11
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• pp.1355-1361
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• 1994

With the availability of ceramics (Al2O3, Al2O3-TiC), it is possible to machine very hard steel at different cutting conditions. When hardened steel STD 11 is turned using ceramic tools, chip formation is observed conical-herical and arc chips with a cyclic saw toothed type. The main cause of saw toothed chip formation is observed conical-herical and arc chips with a cyclic saw toothed type. The main cause of saw toothed chip formation is found to be periodic gross shear fracture extending from the free surface of the chip toward the tool tip. In regard to chip control, ceramic Al2O3 is superior to the other cutting tools. The roughness of machined surface was getting worse with increasing of cutting speed and feed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.4 no.4
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• pp.14-20
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• 2005

This paper deals with the study of feasibility of rotary carbide tools in the machining of aluminium alloy. A rotary tool holder was designed and manufactured for this work. Experiments were performed using Taguchi methods and regression analysis to analyse the influence of various factors and their interactions on the cutting characteristics of rotary carbide tools during machining. The cutting force is influenced the most greatly at the inclination angle. The surface roughness is influenced distinctly at depth of cut. It deduced an equation to predict cutting force and surface roughness. Hence, it could be concluded here that the proposed model agrees with the experimental data satisfactorily.

• Korean Journal of Computational Design and Engineering
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• v.3 no.3
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• pp.177-182
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• 1998

The computer related techniques have been developed rapidly in the field of metal removal industry. The electronic catalog for mechanical elements is one of such developments realized in recent years. As the emergence of the electronic catalogs in the 90s, it breaks the restriction of the traditional catalog and becomes a helpful and efficient tool in the field. In this paper, we develop an electronic catalog for the cutting tools of the Korea Tungsten Co. Ltd. The catalog consists of three parts: a preprocessor for tool selection, a database for tool, and a postprocessor for search result. A preprocessor for tool selection is developed under a user-friendly consideration. A database for tool consists of milling, drilling, and reaming tools with a list of cutters, inserts, and components. A postprocessor for search result consists of weight, dimension. drawing, product order number etc. of the tools. It also suggests the optimized cutting condition of the selected tool using a neural network technique which is done by an independent research group.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.9
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• pp.1520-1530
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• 1997

Machining pressed compacts of ceramic and WC-Co materials can be the most cost effective way of forming the bodies prior to sintering when the required number of pieces is small. In this study, in order to clarify the machinability for turning, the $Si_3N_4$ and the WC-Co green compacts unsintered were machined under different cutting conditions with various tools. Absorbing chips by vacuum hose decreases tool wear. The tool wear becomes larger in the order of the ceramic, CBN and cemented carbide tools in machining the $Si_3N_4$ green compacts. In machining the WC-Co green compacts, the tool wear becomes larger in the order of the ceramic, cemented carbide and CBN tools. The land of cutting edge does not affect tool wear. When machining with cemented carbide tool, the tool wear i equal cutting length is nearly identical in spite of the increase of cutting spee, and the roughness of machined surface was the best in the cutting speed of 90 m/min. The tool wear decreases with the increase of rake angle and relief angle and with the decrease of nose radius. The machined surfaces become worse with the increase of feed rate and depth of cut, and with the decrease of rake angle and relief angle. The tool wear is not affected by the feed and depth of cut.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.59-65
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• 2003

Four kinds of $Si_3N_4$-based ceramic cutting tools with different sintering time were fabricated to investigante the effect of sintering time on the microstructure, mechanical properties, grain sizes and the cutting performance. An endeavor was also made to determine the relation among mechanical property, Brain size and tool life. $Si_3N_4$ home made cutting tool sintered for 1 hour under $1760^{\circ}$ temperature and 25MPa pressure showed the best cutting performance among selected ceramic tools during machining both Bray cast iron and heat treated SCM440. Multiple linear regression model was used to estimate the tool lift from mechanical property, grain size and showed good result. It was also shown that hardness imposed the biggest offect on tool life.