• Journal of the Korean Society for Precision Engineering
• /
• v.16 no.3 s.96
• /
• pp.47-52
• /
• 1999

Theoretical and experimental studies on burr formation and deburring in many manufacturing processes have been actively pursued. Though micro-drilling has become more important in the production of precision parts such as PCB, air bearing, camera and nozzle, most studies on drilling burr formation have focused on the conventional drilling process. This paper describes burr formation process and the effect of cutting conditions such as spindle speed, feedrate and drilling depth per one step on burr formation in drilling A6061 with drills of diameter 1.0mm and 0.6mm. Experimental results showed that burr with cap were formed at relatively low feedrates, while petal burrs with several large burr fragments were formed at high feedrates. Burr height appeared to increase at the hight feedrates and lower spindle speeds. The effect of final cutting depth on burr height was negligible.

• Journal of the Korean Society for Precision Engineering
• /
• v.11 no.2
• /
• pp.50-64
• /
• 1994

Cutter deflections in the ball-end milling process is one of the main causes of the machining errors on a free-form surface. In order to avoid machining errors in this process, a methodology avoiding these machining errors on the free-form surfaces has been developed. In this method, feedrates in the finish cuts are adjusted for the prevention of machining errors. A model for the prediction of machining errors on the free-form surface is analytically derived as a function of feed and normal vector at the surface of contact point by the cutter. This model is applied to the dertermination of the adjusted feedrates which satisfy the machining tolerance of the surface. In the finish cuts of a simple curved surface, the suggested model is examined by the measurements of the generated machining error on this surface. And also, this surface is machined with the adjusted feedrates for the given machining tolerance. The measured machining errors on this surface are compared with the given tolerance. In this comparisons, it is shown that the predicted errors are fairly good agreement with the test results.

• Journal of Industrial Technology
• /
• v.21 no.A
• /
• pp.27-32
• /
• 2001

This paper deals with the study on the culling characteristics in ball-end milling process. First of all, the effects of the geometric cutting conditions such as the spindle speed, feedrates on the surface integrity and machining stability were evaluated by the analytical and the experimental approaches. A large amount of experimental sets are performed to evaluate the effects of chatter phenomenon on the machined surface. The optical microscope and the surface roughness measuring machine are used to measure the surface integrity and roughness of the machined surfaces.

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.5
• /
• pp.116-123
• /
• 2000

This paper presents an NC code post-processor that adjusts feedrates to keep the variation of metal removal rate along the tool paths minimum. Metal removal rate is estimated by virtually machining the part, whose surface model is built from a series of NC codes defined in operation plan, with cutting-tool-assembly models, whose geometry are defined in a machining database. The NC code post-processor modifies the feedrates by the adjustment rules, which are based on the machining knowledge for effective machining. This paper illustrates a procedure fur grouping machining conditions and we also show how to determine an adjustment rule for a machining-condition group. An example part was machined and it shows that the variation of cutting force was dramatically reduced after applying the NC code post-processor. The NC code post-processor is expected to increase productivity while maintaining the quality of the machined part.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2006.05a
• /
• pp.129-130
• /
• 2006

This paper presents a study on the effect of feedrate changes on the fatigue life of Al 7075-T6 specimens before and after shotpeening. For this purpose. five groups of specimens, each of which consists of eight specimens, were first machined at five different feedrates (0.05, 0.10, 0.15, 0.20 0.25 mm/rev). Half of eight specimens in each group were then peened and the others remained un-peened Finally, the fatigue life of each specimen was measured by using 4-point rotatry bending machine. Comparison of fatigue life among ten sets of specimens is presented.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.9 no.6
• /
• pp.71-81
• /
• 2000

This paper describers a look ahead algorithm of PC-NC(personal computer numerical control). The algorithm is based on acceleration/deceleration before interpolation which doesn\`t include a command error and determines a feedrate value at the end point of each block(or start point of each block). The algorithm is represented as following; 1) calculating two maximum arrival feedrates(F$_1$,F$_2$) by an acceleration value, a command feedrate, and the distance of a NC block, 2) getting a tangent feedrate (F$_3$) of the adjacent blocks, 3) choosing a minimum value among these three feedrates, and 4) setting the value to a feedrate of a start point of the next block(or a end point of the previous block). The proposed look ahead algorithm was implemented and tested by using a commercial TROS(real time operation system) on the MS-Windows NT 4.0 in a PC platform. For interfacing to a machine, a counter board, a DAC board and a DIO board were used. The result of the algorithm increased a machining precision and a machining speed in many short blocks.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2002.04a
• /
• pp.94-99
• /
• 2002

Increasing demands on precision machining of 3D free-form surface have necessitated the tool smoothly varying feedrates. This paper presents on of algorithm for adaptive feedrate on NURBS curve. Since the algorithm for calculating variable feedrate depends on the curvature of curve, it permits to get constant material tool can be protected un terms of tool chipping vibration, etc.

• Journal of Mechanical Science and Technology
• /
• v.17 no.3
• /
• pp.336-342
• /
• 2003

Increasing demand on precision machining using computerized numerical control (CNC) machines have necessitated that the tool move not only with the smallest possible position error but also with smoothly varying feedrates in 3-dimensional (3D) space. This paper presents the simultaneous 3D machining process investigated using a retrofitted PC-NC milling machine. To achieve the simultaneous 3-axis motions, a new precision interpolation algorithm for 3D Non Uniform Rational B-Spline (NURBS) curve is proposed. With this accurate and efficient algorithm for the generation of complex 3D shapes, a real-time NURBS interpolator was developed using a PC and the simultaneous 3D machining was accomplished satisfactorily.

• Journal of Industrial Technology
• /
• v.17
• /
• pp.11-20
• /
• 1997

This paper deals with the study on the cutting characteristics in ball endmilling process. First of all, the effects of the geometric cutting conditions such as the cutting speed, feedrates and the path interval on the surface integrity were evaluated by the analytical and the experimental approaches. Secondly, the cutting mechanism model was developed to predict the cutting force accurately. Prediction of cutting force make it possible to predict the shape error, estimate system stability and build the reliable adaptive control system. A large amount of experimental set are performed to show the validities of the proposed theories and to investigate the effect of cutting geometry such as rubbing effects, burr effects and etc.

• Korean Journal of Computational Design and Engineering
• /
• v.12 no.1
• /
• pp.1-7
• /
• 2007

In this paper, we present a machining time estimation algorithm for 5-axis high-speed machining. Estimation of machining time plays an important role in process planning and production scheduling of a shop. In contrast to the rapid evolution of machine tools and controllers, machining time calculation is still based on simple algorithms of tool path length divided by input feedrates of NC data, with some additional factors from experience. We propose an algorithm based on 5-axis machine behavior in order to predict machining time more exactly. For this purpose, we first investigated the operational characteristics of 5-axis machines. Then, we defined some dominant factors, including feed angle that is an independent variable for machining speed. With these factors, we have developed a machining time calculation algorithm that has a good accuracy not only in 3-axis machining, but also in 5-axis high-speed machining.