• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.5
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• pp.1-7
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• 2016

In the present study, a plastic surface end-milling was implemented to investigate the effects of processing parameters on surface quality. The end milling can be considered an efficient method for rapid prototyping of thermoplastic bio-systems since it exhibits several beneficial functions including short fabrication time and high dimensional accuracy. In this regard, putative biocompatible thermoplastic materials, such as PMMA, PET, and PC, were chosen as workpiece materials. Among the relevant processing parameters influencing the surface quality of the final product, depth of cut, feed rate, and spindle speed were considered in the present study. The roughness of surfaces machined under various conditions was measured to elucidate the effect of each parameter. We found that the cut depth was the most significant factor. Heat generation during machining also had a remarkable effect. From these investigations, an appropriate combination of processing conditions specific to each type of use and end-product could be found. This optimization can be useful in end-milling of thermoplastic bio-systems.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.7 s.178
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• pp.1681-1688
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• 2000

A dynamic model for the prediction of surface topography in high speed end milling process is developed. In this model the effect of tool runout, tool deflection and spindle vibration were taken in to account. An equivalent diameter of end mill is obtained by finite element method and tool deflection experiment. A modal parameter of machine tool is extracted by using frequency response function. The tool deflection, spindle vibration chip thickness and cutting force were calculated in dynamic cutting condition. The tooth pass is calculated at the current angular position for each point of contact between the tool and the workpiece. The new dynamic model for surface predition are compared with several investigated model. It is shown that new dynamic model is more effective to predict surface topography than other suggested models. In high speed end milling, the tool vibration has more effect on surface topography than the tool deflection.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.4
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• pp.34-43
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• 2002

The purpose of this paper is to further extend the theoretical understanding of the dynamic end milling process and to derive a computational model to predict the milling force components. A comparative assessment of different cutting force models is performed to demonstrate that the instantaneous shear plane based formulation is physically sound and offers the best agreement with experimental results. The procedure f3r the calculation of the model parameters used in the cutting force model, based on experimental data, has been presented. The validity of the proposed computational model has been experimentally verified through a series of cutting tests.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.985-988
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• 1997

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 in up end milling process using measured cutting forces. Size effect was identified from the analysis of specific cutting resistance obtained by using the modified undeformed chip section area.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.6
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• pp.1-9
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• 2004

For improvement of productivity and cutting tool lift, cutting force in end milling needs to be predicted accurately. In order to analyze cutting force, the cutting dynamics was modelled mathematically by using chip load, cutting geometry, and the relationship between cutting forces and the chip load. Specific cutting force coefficients of the cutting dynamics model were obtained by average cutting forces, tool diameter, cutting speed, fled, axial depth and radial depth of cut. The effects of the cutting conditions on the specific cutting force constants in milling were studied. The model is verified through comparisons of model predicted cutting forces with measured cutting forces obtained from machining experiments.

• Advances in materials Research
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• v.7 no.2
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• pp.137-148
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• 2018

The present paper is a contribution in characterising end milling process of AISI 52100 ball bearing steel through statistical analyses of variance (ANOVA). The latter has been performed to identify the effect of the cutting parameters on the machined surface roughness and the cutting tool life. Wear measurements have been carried on multilayer coated carbide inserts and the respective surface roughness has been recorded. Taguchi's technique has been adapted to conduct the design experiments in terms of orthogonal arrays according to the cutting parameters (cutting speed, feed rate and depth of cut), the type of coating (TiN, TiCN, TiAlN) and lubricating condition. Regression analyses have conducted to the development of simplified empirical models that can be effectively used to predict surface roughness and tool wear in the present milling process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.119-124
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• 1996

End milling operation is very important in machining precision components. Deterioration of surface roughness and surface geometry will cause more process for surface finishing. According to the feed rate and the cutting edge geometry, the cusp which is geometrically uncut surface is determined. To reduce the cost for dinishing operation after end milling, the cusp must be remaianed in small size as possible. Due to the cylindrical type of the end mill, tool deflection is one of the main problems in surface generation. The cutting resistance and the rigidity of the end mill will determine the size of tool deflection. One more important factor which deteriorate surface quality comes from the error in manufacturing end mills. Run-out of end mill which is the difference of the radius of each cutting edges will produce the difference of the cusp size in every rotation of end mill. These three major factors to the surface quality will be analized and the result will be compared with experimental ressult.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.272-277
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• 2003

In order to predict vibration during end-milling process, the cutting dynamics was modelled by using neural network and combined with structural dynamics by considering dynamic cutting states. Specific cutting constants of the cutting dynamics model were obtained by averaging cutting forces and tool diameter, cutting speed, feed, axial depth radial depth were considered as machining factors. Cutting farces by test and by neural network simulation were compared and the vibration during end-milling was simulated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.678-682
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• 1996

Acoustic emission(AE) is monitored during end milling with a sensor attached to the cutting fluid discharge nozzle. Cutting forces are also measured and compared with the AE signals to examine the reliability of the AE signals. It is demonstrated that the AE signals provide reliable informations about the cutting processes and tool states. Moreover, edge chipping and fracture of tools can be successfully detected using both the AE signals and cutting forces.

• Journal of Powder Materials
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• v.5 no.1
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• pp.64-70
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• 1998

Milling media of steel and partially stabilized zirconia(PSZ) were used to produce $Mo_3$Si by mechanical alloying(MA) of Mo-25.0at%Si elemental powder mixture. The effect of milling medium materials on MA of the powder mixture have been investigated by XRD and DTA. The reaction rate and the end-product noticeably depended upon the milling medium material. The formation of $Mo_3$Si and $Mo_5Si_3$phases by PSZ ball-milling took place after 15 hr of MA and was characterized by a slow reaction rate as Mo, Si, $Mo_5Si_3$ and $Mo_3$Si coexisted for a long period of milling time. The formation of a new phase by steel ball-milling, however, did not take Place even after 96 hr of MA. DTA and annealing results showed that $Mo_5Si_3$ and $Mo_3$Si were formed after heating the ball-milled powder specimens to different temperatures. At low temperatures, Mo and Si were transformed into $Mo_5Si_3$. At high temperatures, the formation of $Mo_3$Si can be partially attributed to the reaction, 7Mo+Si+$Mo_5Si_3$-.4$Mo_3$Si . The formation of $Mo_3$Si and Mo5Si3 phases by mechanical alloying of the powder mixture and the relevant reaction rate appeared to depend upon the milling medium material as well as the thermodynamic properties of the end-products.