• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.2
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• pp.87-94
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• 2002

In domestic industry, there is no manufacturers specialized in the production of cutting tools for the difficult cutting materials. Then, we have flew data about them. In this study, the gear driving high speed lathe on which is mounted by a tool dynamometer and high speed CCTV were used to measure the various machining characteristics. Relations among the cutting speed, feed rate per revolution, cutting depth, cutting forces and surface roughness ware graphically analyzed under 64 cutting conditions. The process of chip, i.e., generation, development and falling-off also were visualized for the characterization of chip shapes of the difficult-to-cut materials using the CCTV.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.266-269
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• 2002

Research during the past several years has established the effectiveness of acoustic emission (AE)-based sensing methodologies for machine condition analysis and process. AE has been proposed and evaluated for a variety of sensing tasks as well as for use as a technique for quantitative studies of manufacturing process. STD11 has been known as difficult-to-cut materials. For this study, the micro-grooving machine was developed. The experiments were performed using diamond blade and CBN blade f3r machining STD11. Evaluating the machining conditions, frequency spectrum analysis of acoustic emission (AE) signals according to each conditions were applied.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2005.04a
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• pp.245-248
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• 2005

During manufacturing thick composite cylinders, large thermal residual stresses are developed and induce catastrophic interlaminar failures. Since the residual stresses are dependent on many process parameters, such as temperature distribution during cure, cure shrinkage, winding tension, and migration of fibers, calculation of the residual stresses is very difficult. Therefore a radial-cut method have been used to measure the residual stresses in the composite cylinders. But the conventional radial-cut method needs to know numerous material properties which are not only troublesome to obtain but also vary with change of fiber arrangement during consolidation. In this paper, a new radial-cut method with cut-cylinder-bending test was proposed and the measured residual stresses were compared with calculated thermal residual stresses. It was found that the new radial-cut method which does not need to know any of material properties gave better estimation of residual stresses regardless of radial variation of material properties. Additionally, interlaminar tensile strength could be obtained by the cut-cylinder-bending test.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.52-57
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• 2000

STD11 is one of difficult-to-cut materials and its cutting characteristic data is not built enough. A bad cutting condition of it leads to low productivity of die and mould, so it is necessary to evaluate the machining characteristics of STD11. In this paper, the relations of the geometry of ball-end mill and mechanics of machining with it are studied. The helix angle of ball-end mill varies according to a location of elemental cutting edge in the cutting process are difficult to calculate accurately. To calculate instantaneous cutting forces, it is supposed that the tangential, radial and axial cutting force coefficients are functions of elemental cutting edge location. Elemental cutting forces in the x,y and z direction are calculated by coordinate transformation. The total cutting forces are calculated by integrating the elemental cutting forces of engaged cutting edge elements. This model is verified by slot and side cutting experiments of STD11 workpiece which was heat-treated to HRC45.

• Journal of the Korean Society of Safety
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• v.24 no.1
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• pp.1-6
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• 2009

In machining of ceramic materials, they are very difficult-to cut materials because of there high strength and hardness. Machining of ceramics are characterized by cracking and brittle fracture. Generally, ceramics are machined using conventional method such as grinding and polishing. However these processes are generally costly and have low MRR(material removal rate). This paper focuses on machinability evaluation of machinable ceramics for products with CNC machining center. Thus, in this paper, experiment applying cutting parameters is performed based on experimental design method. A design and analysis of experiments is conducted to study the effects of these parameters on the surface roughness by using the S/N ratio, analysis of ANOVA, and F-test. And multiple linear regression analysis is applied to compare experimental with predicted data in consideration of surface roughness. Cutting parameters, namely, feed, cutting speed and depth of cut are used to accomplish purpose of this paper. Required experiments are performed, and the results are investigated.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.38-44
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• 2008

Titanium and its alloys, due to their superior properties of high specific strength and excellent corrosion resistance, are increasingly used in living applications in the 21century. The applications in aerospace and medical industries demand machining process more frequently to obtain a desired product. But unfortunately, this material is one of the most difficult-to-cut. In the turning process of titanium alloys, the key point for successful work is to select proper tool materials and cutting conditions. This study suggests a guidance for selecting the tool materials and the cutting speeds to improve tool life and surface integrity in Ti-6Al-4V titanium turning process. The experiments investigate the change of surface roughnesses, cutting forces and flank wear with various cutting parameters of tool materials, depth of cuts and feeds. As the results, K10 type of insert tip was assured as the best for turning of Ti-6Al-4V titanium alloy.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.4 s.175
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• pp.900-906
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• 2000

Ceramic, PCD and CBN tools are available for the difficult-to-cut-materials such as hardened carbon tool steel, stainless steel, Inconel 718 and etc. Ceramic tools are likely to be chipped and abruptly broken before the appearance of normal wear in turning. Ceramic tools are suitable for continuous in turning, not for intermittent in milling. In this study, TiN/TiCN multi-layer coated ceramic tools were found to restrain the chipping, breaking and early fracture and to increase the critical cutting speed owing to TiN/TiCN multi-layer coating in Arc Ion Plating of PVD method.

• Design & Manufacturing
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• v.2 no.5
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• pp.43-47
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• 2008

Micro Electrochemical Machining(Micro ECM) has traditionally been used in highly specialized fields such as those of the aerospace and defense industries. It is now increasingly being applied in other industries where parts with difficult-to-cut material, complex geometry and tribology such as compute. hard disk drive(HDD) are required. Pulse Electrochemical Micro-machining provides an economical and effective method for machining high strength, high tension, heat-resistant materials into complex shapes such as turbine blades of titanium and aluminum alloys. Usually aluminum alloys are used bearings to hard disk drive in computer. In order to apply aluminum alloys to bearing used in hard disk drive, this paper presents the characteristics of Micro ECM for aluminum alloy.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.1
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• pp.61-70
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• 2004

Generally, ceramics are very difficult-to-cut materials because of its high strength and hardness. The machining process of ceramics can be characterized by cracking and brittle fracture. In the machining of ceramics, edge chipping and crack propagation are the principal reasons to cause surface integrity deterioration. Such phenomenon can cause not only poor dimensional and geometric accuracy, but also possible failure of the ceramic parts. Ceramics can be machined with traditional method such as grinding and polishing. However, such processes are generally cost-expensive and have low material removal rate. Thus, in this paper, to overcome these problems. BN powder, which gives good cutting property, is added for the fabrication of machinable ceramics by volume of 5,10,15,20,25 and 30%. And, mechanical properties, R-curve behavior and machining tests are carried out to evaluate the machining properties of the manufactured machinable ceramics.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.214-217
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• 2002

Micro Surface Electrochemical Machining has traditionally been used in highly specialized fields such as those of the aerospace and defense industries. It is now increasingly being applied in other industries where parts with difficult-to-cut material, complex geometry and tribology such as compute. hard disk drive(HDD) are required. Pulse Electrochemical Micro-machining provides an economical and effective method for machining high strength, high tension, heat-resistant materials into complex shapes such as turbine blades of titanium and aluminum alloys. Usually aluminum alloys are used bearings to hard disk drive in computer. In order to apply aluminum alloys to bearing used in hard disk drive, this paper presents the characteristics of Micro Surface Electrochemical machining for aluminum alloy.