• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2001년도 춘계학술대회 논문집
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• pp.1021-1024
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• 2001

Out of all metal-cutting processes, the hole-making process is the most widely used. It is estimated to be more than 30% of the total metal-cutting process. It is therefore desirable to monitor and detect drill wear during the hole-drilling process. In this paper, the vision system of the sensing methods of drill flank wear on the basis of image processing is used to detect the wear pattern by non-contact and direct method and get the reliable wear information about drill. In image processing of acquired image, median filter is applied for noise removal. The vision flank wear area of the drill was measured. Backpropagation neural networks (BPns) were used for no-line detection of drill wear. The neural network consisted of three layers: input, hidden and output. The input vectors comprised of spindle rotational speed, feed rates, vision flank wear, thrust and torque signals. The output was the drill wear state which was either usable or failure. Drilling experiments with various spindle rotational speed and feed rates were carried out. The learning process was peformed effectively by utilizing backpropagation. The detection of the abnormal states using BPNs achieved 96.4% reliability even when the spindle rotational speed and feedrate were changed.

• 한국정밀공학회지
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• 제32권5호
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• pp.423-429
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• 2015

Linear motion (LM) ball guides have good accuracy and high efficiency. They are widely applied for precision machinery such as machine tools, semiconductor fabrication machines and robots. However, friction force incurs heat between the balls and grooves. Thermal expansion due to the heat deteriorates stiffness and accuracy of the LM ball guides. For accurate estimation of stiffness and accuracy during the linear motion, friction models of LM ball guides are required. To formulate accurate frictional models of LM ball guides according to load and preload conditions, rolling and viscous frictional analyses have been performed in this paper. Contact loads between balls and grooves are derived from Hertzian contact analysis. Contact angle variation is incorporated for the precision modeling. Viscous friction model is formulated from the shear stress of lubricant and the contact area between balls and grooves. Experiments confirm validity of the developed friction model for various external load and feedrate conditions.

• 한국공작기계학회논문집
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• 제13권5호
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• pp.30-37
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• 2004

This paper presents the thermal characteristic analysis of a high-speed horizontal machining center with spindle speed of 50,000rpm and feedrate of 120m／min. The spindle system is designed based on the built-in motor, angular contact ceramic ball bearings, oil-air lubrication and oil-jacket cooling method. The X-axis and Y-axis feeding systems are composed of the linear motors and linear motion guides, and the Z-axis feeding system is composed of the servo-motor, ball screw and linear motion guides. The thermal characteristics such as the temperature distribution, temperature rise, thermal deformation and step response, are estimated based on the finite element model of machining center and the heat generation rates of heat sources related to the machine operation conditions. Especially, the thermal time constant assessed from the step response function is introduced as an index of thermal response characteristics.

• 대한기계학회논문집A
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• 제27권11호
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• pp.1958-1966
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• 2003

Three-axis CNC surface machining entails a series of processes including rough cutting, intermediate cutting and finish cutting for a reference surface defined in CAD/CAM. This study is targeting development of an integrated NURBS surface interpolator that can incorporate rough, intermediate and finish cutting processes. In each process, volume to be removed and cutting condition are different according to the shape of a part to be machined and the reference surface. Accordingly, the proposed NURBS surface interpolator controls motion in real-time optimized for the machining conditions of each process. In this paper, a newly defined set of G-codes is proposed such that NURBS surface machining through CNC is feasible with minimal information on the surface composition. To verify the usefulness of the proposed interpolator, through computer simulations on NURBS surface machining, total machining time, size of required NC data and cutting force variations are compared with the existing method.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 춘계학술대회 논문집
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• pp.457-458
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• 2006

A method for obtaining smooth, jerk bounded feed rate profile in high speed machining has been developed. This study proposes a NURBS interpolator based on adaptive feed rate control with a well developed look ahead algorithm which takes into account the machining dynamics as well. Limitation of jerk and proportional torque rate result in smoothened loads on the machine which effectively reduces excitation of the resonant frequencies of the machine. It is found that the values of the feed rate of the down stream sharp corner have profound effect on the feed rate of the upstream sharp corners. By using a windowing scheme the feed rate profile obtained after look ahead method is re-interpolated to reduce the jerk related problems. This is compared with the adaptive NURBS interpolator to show the effectiveness of the proposed method. Simulation results indicate that the consideration of 'ripple effect' is important in avoiding jerk and thereby increasing the machining accuracy.

• 한국정밀공학회지
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• 제23권2호
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• pp.73-80
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• 2006

High speed machining(HSM) technique is widely used in the appliance, automobile part and mold industries, because it has many advantages such as good quality, low cost and rapid machining time. But it also has problems such as tool breakage, smooth tool path, and so on. In particular, small size end mill is easy to break, so it must be changed before interrupting operation. Generally, the tool life of small size end mill is affected by the milling conditions whose selected parameters are spindle speed, feedrate, and width of cut. The experiments were carried out by full factorial design of experiments using an orthogonal array. This paper shows optimal combination and mathematical model for tool life, Therefore, the analysis of variance(ANOVA) is employed to analyze the main effects and the interactions of these milling parameters and the second-order polynomial regression model with three independent variables is estimated to predict tool life by multiple regression analysis.

• 한국생산제조학회지
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• 제7권5호
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• pp.15-28
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• 1998

Recently may investigations have been studied on the high-speed machining by using machine tools. A CNC machine tool makes some tool path errors caused by software acceleration/deceleration. The faster a cutting feedrate is, the bigger the tool path errors are. Some known methods reduce these kinds of errors, but they make the total cutting time increased. This paper presents a feed-forward algorithm that can be generated by distorting the original tool path, and reduces the tool path errors and the total cutting time. The algorithm to generate a new tool path is represented as following; 1)calculating each distance of software acceleration/deceleration between two adjacent blocks, 2) estimating the distorted distance which is the adjacent-ratio-constant(k1, k2) multiply the distance of software acceleration/deceleration, 3) generating a 3-degree Bezier curve approximating the distorted tool path, 4) symmetrically transforming the Bezier curve about the intersection point between two blocks, and 5) connecting the transformed Bezier curve with the original tool path. The algorithm is applied to FANUC 0M. The study is to promote the high-precision machining and to reduce the total cutting time.

• 대한기계학회논문집
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• 제19권9호
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• pp.2089-2104
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• 1995

A novel and efficient cutter path planning method for machining intricately shaped curved surfaces, called the steepest directed tree method, is presented. The curved surface is defined by triangular facets, the density and structure of which are determined by the intricacy and form accuracy of the surface. Geometrical form definition and recognition of the topological features are used to connect the nodes of the triangulated surface meshes for the successive and interconnected steepest pathways, which makes good use of end milling characteristics. The planetary cutter centers are determined to locate along smoothly changing paths and then the height values of the cutter are adjusted to avoid surface interference. Several machined examples of intersecting and intricate surfaces are presented to illustrate the benefits of the new approach. It is shown that due to more consistent geometry matching between cutter and surface(in comparison with the current CC Cartesian method) surface finish can be typically improved. Moreover, the material in concave fillets which is difficult to be removed by ball mills can be removed efficiently. The built-in positioning of cutter to avoid interference runs minutely in the sharp and discontinuous regions. The steepest upward movement of the cutter gives a stable dynamic cutting state and allows increase in the feedrate and spindle speed while remaining the stable cutting state.

• 대한기계학회논문집A
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• 제27권9호
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• pp.1499-1507
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• 2003

Physical importance of cutting temperatures has long been recognized. Cutting temperatures have strongly influenced both the tool life and the metallurgical state of machined surfaces. Temperatures in drilling processes are particularly important, because chips remain in contact with the tool for a relatively long time in a hole. Tool temperatures tend to be higher in drilling processes than in other in machining processes. This paper concerns with modeling of thermal behaviors in drilling processes as well as estimation of the cutting temperature distribution based on remote temperature measurements. One- and two-dimensional estimation problems are proposed to analyze drilling temperatures. The proposed thermal models are compared with solutions of finite element methods. Observer algorithms are developed to solve inverse heat conduction problems. In order to apply the estimation of cutting temperatures, approximation methods are proposed by using the solution of the finite element method. In two-dimensional analysis, a moving heat source according to feedrate of the drilling process is regarded as a fixed heat source with respect to the drilling location. Simulation results confirm the application of the proposed methods.

• 한국기계가공학회지
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• 제19권11호
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• pp.64-69
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• 2020

To determine the effective factors for microparticle blasting with precise sequence position control in the x-axis and y-axis directions, we conducted a statistical experimental analysis of blasted square shapes by considering five condition factors. The control input and output were operated simultaneously by rotation-linear motion conversion and fine particles were blasted onto the aluminum specimen by precise position control driving using multiple execution codes. The micro-driving device used for processing was capable of microparticle blasting and of controlling the system through contact with a limit sensor at high speed and a two-degree-of-freedom driving mechanism. Our experiments were conducted on 1,050 specimens of pure aluminum (containing <1% of other elements). The effects of several factors (e.g., particle and nozzle diameters, blasting pressure, and federate and blasting cycle numbers) on the surface roughness and blasted surface's depth were verified through a statistical experimental analysis by applying the dispersion analysis method. This statistical analysis revealed that the nozzle diameter, the blasting pressure, and the blasting cycle number were the dominant factors.