• 반도체디스플레이기술학회지
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• 제16권2호
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• pp.79-84
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• 2017

This paper outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in end milling when machining STS304 with TiAlN coated SKH59 tool under up and down end milling conditions. The end milling parameters evaluated are depth of cut, spindle speed and feed rate. An orthogonal array, signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are employed to analyze the effect of these end milling parameters. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer resources than a factorial design. An orthogonal array of $L_9(33)$ was used. The most important input parameter for cutting force, however, is the feed rate, and depending on the cutter rotation direction. Finally, confirmation tests verified that the Taguchi design was successful in optimizing end milling parameters for cutting force.

• 대한기계학회논문집B
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• 제28권3호
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• pp.265-270
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• 2004

Experiment study on a down scaled two-phase catalytic reactor is presented. As a preliminary step for the development of catalytic reactor, nano-particulate catalyst was prepared. Perovskite La$\_$0.8/Sr$\_$0.2/CoO$_3$is chosen and synthesized as a catalyst considering superior catalytic performance in reduction and oxidation process where oxygen is involved among the reagent. Reactor that has a scale of 2${\times}$10${\times}$25mm was made by machining of A1 block as a layered structure considering further extension to micro-machining. Hydrogen peroxide of 70wt% was adopted as reactant and was provided to the reactor loaded with 1.5 g of catalyst. Reactant flow rate was varied by precision pump with a range of 0.15cc/min to 17.2cc/min. Temperature distribution within reactor was recorded by 3 thermocouples and total amount of liquid product was measured. Temperature distribution and factors that affect temperature were observed and relation between temperature distribution and production rate was also analyzed. Relative time scale plays a significant role in the performance of the reactor. To obtain steady state operation, appropriate ratio of flow rate, catalyst mass and reactor geometry is required and furthermore to get more efficient production rate temperature distribution should be evenly distributed. The database obtained by the experiment will be used as a design parameter for micro reactor.

• 한국생산제조학회지
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• 제22권1호
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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.

• 대한기계학회논문집B
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• 제37권12호
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• pp.1159-1165
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• 2013

파우더 블라스팅은 미세 유리가공법으로서 가공속도가 빠르고 저비용의 장점이 있지만 유리를 취성파괴 시키기 때문에 표면거칠기가 좋지않다. 블라스팅된 표면에 저압의 워터젯을 분사하여 표면에서의 연마 슬러리의 흐름을 통해 표면거칠기를 저감할 수 있다. 본 연구에서는 소다라임 유리에 블라스팅으로 마이크로 채널을 가공한 후 워터젯을 연속 적용하고, 마이크로 채널의 표면거칠기 및 단면 형상의 변화의 과정을 관찰하였다. 워터젯의 적용결과, 초기단계에서는 블라스팅에 의한 미세 요철이 제거되었고, 이후 표면하부의 크랙이 제거되어 평균 표면거칠기 50 nm 근방의 매끈한 표면을 얻을 수 있었다. 표면거칠기 저감에 동반하여 채널단면의 확장 과정도 함께 관측하였다. 마지막으로 제안한 방법에 의해 미세유체칩의 가공 결과를 제시하였다.

• International Journal of Precision Engineering and Manufacturing
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• 제5권3호
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• pp.35-42
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• 2004

This research describes that the cutting characteristics and tool wear behavior in the micro cutting of three kinds of wear resistant cemented carbides (WC-Co; V40, V50 and V60) using PCD (Poly Crystalline Diamond) and PCBN (Poly crystalline Cubic Boron Nitride) cutting tools by use of the SEM (Scanning Electron Microscope) direct observation method. The purpose of this research is to present reasonable cutting conditions from the viewpoint of high efficient cutting refer to a precise finished surface and tool wear. Summary of the results is as follows: (1) The cutting forces tend to increase as the increase of the weight percentage of WC particles, and the thrust forces was larger than the principal forces in the cutting of WC-Co. These phenomena were different from the ordinary cutting such as cutting of steel or cast iron. (2) The cutting speed hardly influenced the thrust force, because of the frictional force between the cutting tool edge and small WC particles at low cutting speed region such as 2$\mu\textrm{m}$/s. It seemed that the thrust cutting force occurred by the contact between the flank face and work material near the cutting edge. (3) The wear mechanism for PCD tools is abrasion by hard WC particles of the work materials, which leads diamond grain to be detached from the bond. (4) From the SEM direct observation in cutting the WC-Co, it seems that WC particles are broken and come into contact with the tool edge directly. This causes tool wear, resulting in severe tool damage. (5) In the orthogonal micro cutting of WC-Co, the tool wear in the flank face was formed bigger than that in the rake face on orthogonal micro cutting. And the machining surface integrity on the side of the cutting tool with a negative rake angle was better than that with a positive one, as well as burr in the case of using the cutting tool with a negative rake angle was formed very little compared to the that with a positive one.

• Journal of Biosystems Engineering
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• 제16권3호
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• pp.228-238
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• 1991

Cam plays very important roles due to continuous requirement for the high-speed and automation of the machinery. A large number of studies of cam curve were carried out by many researchers, and CNC milling and machining center for manufacturing cam have been widely used recently. The purpose of this study was to develop a CAD/CAM system for cam using QuickBasic language in 16-bit PC for application of cam design and manufacturing. Results obtained were as follows : 1. It was possible to input data by entering cam angle and its corresponding R, from 0 to 360 deg. of cam angle. The tediousness at entering data was minimized because of the same data format for both cylindrical cam and disc cam, and free format used for data file. 2. It was possible to design cam by choosing only the number of cam curve because of developing the CAD/CAM program with dimensionless method of cam curves including widely used 19 kinds. After selecting the number of the cam curve, the CAD/CAM system automatically shows the characteristics of cam motion enough to help a designer to decide : displacement, velocity, acceleration and jerk. 3. It was possible to execute, in an efficient way, both the cam profile synthesis and the generation of NC program for CNC machining center by using the input data. 4. This NC program generated by the CAD/CAM system developed here, was evaluated as positive in relation with actual manufacturing experiments and thought to be useful in its application without any modification. It can be said that this CAD/CAM system could be used by the beginners to design and manufacture the cam automatically as the system consists of very simple dialogue methods. In addition, self-developed QuickBasic would be would used as a basic tool for further stuides in this area of research, together with application.

• 한국기계가공학회지
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• 제20권8호
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• pp.93-98
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• 2021

The complex effects of the machining parameters make it is difficult to control and predict surface roughness. The theoretical surface roughness observed during mechanical machining with a round tool is determined by the tool radius and pitch. However, it was revealed that other parameters, such as the depth of cut and cutting speed, also affect surface roughness. This study adapted the Taguchi method, which can analyze the effects of cutting parameters quantitatively with an efficient number of experiments, to optimize the parameters for better surface roughness. Experiments were designed based on an orthogonal array, and the quantitative effects on the surface roughness were analyzed using the S/N ratio. The surface roughness was affected by all parameters, especially the tool radius. The optimum cutting parameter values obtained in this study showed better surface roughness than the other combinations of the parameters.

• 한국기계가공학회지
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• 제21권1호
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• pp.95-101
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• 2022

This paper proposes a method to process the shape of an optical transmission road and attempts to determine the most suitable single processing method for an acrylic plate optical transmission road. In addition, by manufacturing an automatic pattern processing device to generate certain shapes on the acrylic plate at regular intervals, and measuring the illuminance of the patterned acrylic plate optical transmission road, the measured illuminance was confirmed to fall under the KS illuminance values presented in Table 1. In conclusion, when an incident light of approximately 20,000 lx is applied, the transmission illumination is approximately 200 lx, which represents a transmission rate of approximately 1% for incident light and corresponds to the KS illumination criterion F. Additionally, the right-angle triangular pyramid base size (A) processed at a temperature of 350 ℃ for one second was 2 mm, exhibiting the largest transmission illumination of 280 lx. When the transparent acrylic plate was set to a constant size of 1.6 mm at the bottom of the right-angle triangular pyramid, the fastest response occurred at a processing tip temperature of 350 ℃ (0.04 s). On the other hand, it took 10 s to process the size of the bottom of the right-angled triangular pyramid at a temperature of 200 ℃ to 1.6 mm, and it was confirmed that the optical transmission efficiency was significantly reduced because of the burr that occurred at this time.

• 한국산업정보학회논문지
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• 제14권4호
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• pp.1-7
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• 2009

이 논문은 다목적 공정순서계획 알고리즘을 소개한다. 공정순서계획이란 가용한 기계들을 이용하여 원재료를 가공 완료된 부품으로 변형해주는 최적 공정순서들을 결정하는 일이다. 어느 컴퓨터 지원 공정계획 시스템에서나, 가공작업 순서의 결정은 부품 가공이나 부품 도면상의 기술적인 요구사항들을 충족시켜주기 위한 가장 중요한 활동 중의 하나이다. 여기서, 목표는 생산시간, 생산비용, 기계가동률 또는 이들을 복합적으로 만족시켜주는 최적 가공순서를 생성하는 일일 것이다. 파레토 스트라튬 니치 큐비클 (PS NC) 유전 알고리즘이 두 가지 상호 배타적인 기준인 생산비용과 생산품질을 동시에 최적화 시켜주는 가공순서들을 찾는데 이용되었다. 예제에 의한 검증은 제안된 PS NC 유전자 알고리즘이 공정계획문제에 있어서 효과적이며 효율적인 결과를 가져오는 것을 보여준다.

• Steel and Composite Structures
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• 제34권5호
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• pp.681-698
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• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.