• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.1059-1062
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• 1995

In cutting system, relative displacement between rool and workpiece is very important. Even though there have been so many works for modeling cutting process of end-milling, most of them have considered only one displacement of either tool or workpiece instead of both. In this paper, the relative displacement between tool and workpiece is considered for modeling cutting process of end-milling using simple experimental modal analysis and cutting force simulation program is developed. In cutting force model, instantaneous uncut chip thickness model is used and Runge-Kutta method is used for the simulation of time varying cutting system.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.814-817
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• 2000

This paper has two purposes. One is to investigate the effect of the helix angle of endmilling cutter on the cutting haracteristics of inconel 718 in down endmilling. To this end a newly developed cutting force model in down end milling process is presented. Using this cutting force components of 4-tooth endmills with various helix angles have been predicted. Predicted values of cutting force components are well coincide with the measured ones. The other is to compare the down endmilling characteristics of lnconel 718 with those of the up milling previously presented. In up endmilling as the helix angle becomes larger the radial and tangential components of the specific cutting force ($K_1 and K_r$) decrease. While in down milling $K_1 and K_r$ become smaller as the helix angle decrease.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.895-898
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• 2001

This paper presents an optimization cutting speed(OCS) program developed to improve the machining precision and tool life in high speed machining using ball end milling. This program optimized the cutting speed that is changing at any time in free surface machining of an automobile part like a connecting load die. The technique of optimization cutting speed makes the CAD/CAM-generated NC code go through a reverse post process, conducts cutting simulation, and obtain the effective tool diameter of the ball end milling. Then it changes the spindle revolution to within the range of critical cutting speed fit for the material of the workpieces depending upon the effective tool diameter. In this study, the machining precision and tool life were compared for the two connecting load dies processed using the general cutting method and the proposed optimization cutting speed technique, respectively.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.4
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• pp.9-15
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• 2020

Carbon fiber reinforced plastic (CFRP) is a composite material useful in the aerospace and automotive industries because of its light weight and high strength. In this study, side milling tests were carried out using AlCrN, diamond-like carbon (DLC), and diamond-coated end mills. Additionally, a comparison study according to the cobalt content was conducted. Thus, tool wear and surface quality were examined and the influences of using coating and a certain material type were analyzed. The surface roughness of the machined surface was measured. Microscope observations revealed that the CFRP fiber at the machined surface was not damaged even at a cutting distance of 3,000 mm. Therefore, this study showed that the diamond-coated end mill containing 6% cobalt is appropriate for milling CFRP.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.257-262
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• 1999

On End Milling Process predict the cutting force is important. Dynamics the shear stress is the main parameter influencing the energy requirement in machining. It is well known that a nonzero force is obtained when cutting forces measured at different feed rates but otherwise constant cutting conditions are extrapolated to zero feed rate. In this paper, the cutting force measured in end-milling is compared with the simulated force models. The result show that stress measured in cutting is consistent with that stresses predicted.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.3
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• pp.225-231
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• 2011

In this paper, a new end-milling force modelling technique was suggested by considering runout, and its result was compared with real measured force. The specific cutting force is the multiplication of cutting force coefficient and uncut chip thickness. This parameter was used for experimental modelling and prediction of theoretical force. These coefficients, which can be obtained by fitting measured average forces in several conditions, were used for the formulation of theoretical force. The mechanism of end-milling force with runout was developed in this research and its result was verified by comparing the fluctuating theoretical force and its measured one. The fluctuation of force was incurred by a geometric shape of workpiece and its runout in holding. The result of suggested force considering runout shows a good consistency with measured one. So this modelling method can be used effectively for a prediction of end-milling force with runout effect.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.5
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• pp.1-7
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• 2003

In order to predict vibrations occurred during end-milling processes, the cutting dynamics was modelled by using neural network and combined with structural dynamics by considering dynamic cutting state. Specific cutting force constants of the cutting dynamics model were obtained by averaging cutting forces. Tool diameter, cutting speed, fled, axial and radial depth of cut were considered as machining factors in neural network model of cutting dynamics. Cutting farces by test and by neural network simulation were compared and the vibration displacement during end-milling was simulated.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.6
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• pp.1-9
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• 2002

This study describes the geometric characteristics and the 5-axis machining method in order to make end mill cutter coming with insert tips. End mill geometry is consisted of flute part and insert tip part. Flute part modeled by using ruled surfaces with constant helix angle, and insert tip part modeled by rectangular planes containing tapped hole of specified direction in its center. In this study, the modeled insert tip part considered both of a radial rake angle and a axial rake angle, because they were important cutting conditions. In order to machining the virtual end mill defined from geometric characteristics, we programmed a special software to machining the end mill considered in this study. This software can generate NC-codes about following processes, end milling or ball end milling of flute part end milling of rectangular plane, centering of hole, drilling of hole, and tapping of hole. Ant sampled end mills were modeled and machined on 5-axis CNC machining center with two index tables. Since machined end mills were very agreeable to designed end mills, we saw that the method proposed in this study can be very useful for manufacturing of end mill body with insert tip.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.2
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• pp.79-86
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• 2002

In end milling process the undeformed chip thickness and the cutting force components vary periodically with phase change of the tool. In this study, up end milling process is transformed to the equivalent oblique cutting. The varying undeformed chip thickness and the cutting force components in end milling process are replaced with the equivalent average ones. Then it can be possible to analyze the chip-tool friction and shear process in the shear plane of the end milling process by the equivalent oblique cutting system. According to this analysis, when cutting Inconel 718, 61, 64 and 55% of the total energy is consumed in the shear process with the helix angle 30$^{\circ}$, 40$^{\circ}$ and 50$^{\circ}$ respectively, and the balance is consumed in the friction process. With the helix angle of 40$^{\circ}$ the specific cutting energy consumed is smaller than with the helix angle 30$^{\circ}$ and 50$^{\circ}$.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.4
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• pp.104-111
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• 2008

The objective of this study is to evaluate micro end-milling characteristics and tool wear behavior of AlN-hBN composites. First, AlN based composites with hBN contents in the range of 10 to 20vol% were prepared by hot-pressing. Vickers hardness and flexural strength of the prepared composite specimens were measured and compared according to the vol% of hBN variations. Then, cutting force variations were measured and analyzed using a tool dynamometer during the micro end-milling experiments; and machined surface shapes and roughness were investigated using a 3D non-contact type surface profiler. After micro end-milling, worn tools were investigated using a tool microscope and SEM images. From the experimental results, it can be observed that the cutting forces decreased, and surface qualities were improved with increasing hBN contents. At low content of hBN, tool chipping was observed; and tool wear rate decreased with increasing hBN contents. The results of this study insist that proper machining conditions, including tool wear behavior investigation, should be determined for the micro end-milling of AlN-hBN composites for its further application.