• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.10
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• pp.1039-1045
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• 2007

Ultrasonic machining (USM) is suitable for machining hard, brittle and non-conductive materials such as silicon, glass and ceramics. Usually, when micro holes are machined on glass by USM, roundness of hole entrance is poor and cracks appear around the hole exit. In this paper the machining characteristics were studied for roundness improvement and exit crack prevention. From experiments, the tool bending and the shape of tool tip affect hole roundness. When the tool tip is hemispherical, good roundness of holes was obtained. The feedrate and the rotational speed of the tool affect the exit crack. With the machining conditions of 150 rpm in spindle speed and $0.5\;{\mu}m/s$ in feedrate, micro holes with less than $100\;{\mu}m$ in diameter were machined without an exit crack.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.5-14
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• 2002

Hemisphere shapes were machined for different tool paths and machining conditions with ball endmill cutters. It was also found out how feedrate affect the precision of the machining and also tried to study the most suitable feedrate in specific cutting condition. Tool deflection, cutting forces and shape accuracy were measured according to the inclination position of the sculptured surface. As the decreasing of inclination position angle, the tool deflection was increased due to the decreased cutting speed when the cutting edge is approaching toward the center. Tool deflection when upward cutting IS obtained less than that of downward cutting and down-milling in upward cutting showed the least tool deflection for the sculptured surface. For down-milling, the cutting resistance of the side wall direction is larger than that of feed direction. It was found that the tool deflection is getting better as tool path is going to far from the center for convex surface.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.2
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• pp.1-8
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• 2003

Conventionally used linear or circular interpolator is undesirable for the precision machining of 3D free-form surface as the following reason: the transmission errors due to the huge number of data, discontinuity of segmentation, unsmooth motion speed. To this regard, modern CNC machine tools are designed with the function of machining arbitrary parametric curves. However, these systems don't consider the adaptive federate, which dominates the quality of the machining process. This paper proposes a NURBS interpolator for the constant material removal rate. That is accomplished by the variable federate using curvature of curve. The curvature-compensated feederate system has important Potential applications in ensuring part accuracy and protecting cutting tool. The simulated result show it can be applicable to the real machining.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.8
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• pp.1480-1486
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• 2002

In this study, the cross-coupling control (CCC) with three new features is proposed to maintain contour precision in high-speed nonlinear contour machining. One is an improved contour error model that provides almost exact calculation of the errors. Another is the utilization of variable controller gains based on the instantaneous curvature of the contour and the variable command. For this scheme, a stability is analyzed. As a result, the stability region is obtained, and the variable gains are decided within that region. The other scheme in the proposed CCC is a real-time feedrate adaptation module to regulate cutting force fur better surface finish through regulation of material removal rate (MRR). The simulation results show that the proposed CCC system can provide better precision than the existing method particularly in high-speed machining of nonlinear contours.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.10a
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• pp.321-327
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• 1993

In order to maintain the cutting force at a desired level during peripheral end milling processes in spite of variation of the depth of cut and other machining conditions, a feedrate override. Apaptive Control Constraint (ACC) system are developed. Feedrate override was accomplished by a developed MMC board and PMC interface techniques. Nonlinear model of the cutting process was linearized as an adaptive model with time varying paramrters. Integral type estimators were introduced for on-line identification of cutting and control parameters in peripheral and milling processes. Zero Order Jold (ZOH) type degital control methodology which uses pole-placement concepts was applied for the ACC system. Performance of the developed ACC system was confirmed on the vertical machining center equipped with FANUC OMC for a large amount of experiment

• Journal of the Korean Society for Precision Engineering
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• v.19 no.2
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• pp.58-64
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• 2002

In these days, according to increasing the technical development, the dimension of a product goes up for ultra-precision. For the net shape manufacturing, grinding is a important process that influences directly the accuracy and the integrity of produced products. In this study, an experimental evaluation was carried out. Workpiece materials were used STD11, SUS304, and STB2 in accordance with varing condition of feedrate and depth of cut. From measuring the grinding force and the surface roughness, material characteristics of grinding by using CBN wheel were examined.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.397-401
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• 2003

In this work, diamond turning process is used to produce mirror surface on a Al cone. The Al cone as used as a mirror which can reflect a laser beam without scattering and, hence, it is critical to minimize the surface roughness of a Al cone. During diamond turning, feedrate and tool nose radius are changed to investigate characteristics of the ultra precision machined surface of a Al cone. A laser beam of 633 nm is applied to examine the effect of surface roughness on the characteristics of reflectivity. It is found that surface roughness is not significantly affected by feedrate. The main factor influencing surface roughness is tool nose radius. The line patterns of reflected laser beams show that the minimum surface roughness of 0.08 $\mu\textrm{m}$ (Ra) is required to avoid scattering phenomena of reflectivity.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.471-474
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• 2004

In this paper, a NURBS surface interpolator is proposed which can deal with shapes defined from CAD/CAM programs on a surface basis and can improve contour accuracy. The proposed interpolator is based on newly defined G-codes and includes online tool-path planning suitable for NURBS surface machining. The real-time interpolation algorithm, considering an effective machining method for each machining process and minimum machining time, is executed in an online manner. The proposed interpolator is implemented on a PC-based 3-axis CNC milling system and evaluated through actual machining in terms of machining time and regulation of feedrate and cutting force in comparison with the existing method.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.3
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• pp.75-82
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• 2001

The continuous chip in turning operation deteriorates the precision of workpiece and can cause a hazardous condition to operator. Thus the chip form becomes a very important task for reliable turning process. The chip form is identified using the neural network of supervise data Through the measurement of energy radiated from the chip. The feed mechanism os adjusted in order to break continuous chip according to the result of the chip form recognition and it shows a good approach for precision turning operation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.11
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• pp.1053-1058
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• 2007

Micro-EDM technology (or the manufacture of miniature parts is used to make a micro hole. Two electrode shaping methods, mechanical electrode grinding and WEDG technique, have been studied. In this study, an electrode shaping method by using previously machined hole is introduced in order to obtain an optimal hole-making condition. Key factors such as applied voltage, capacitance, feedrate, and hole-dimension have an influence on the fabricating error of electrode shaping, which are taper ratio of a hole, electrode form accuracy, and electrode surface. Therefore, we try to investigate the optimal fabricating of electrode shaping from various experiments. Results from experiments, it was able to minimize the electrode fabricating error as voltage increases, and also applied feedrate and capacitance decreases.