• Journal of the Korean Society for Precision Engineering
• /
• v.15 no.11
• /
• pp.233-243
• /
• 1998

The demand of high speed machining is increasing due to the high speed cutting and grinding provides high efficiency of process, short process time, improved metal removal capacity and better surface finish. Active magnetic bearings allow much high surface speed than conventional ball bearings and therefore greatly suitable for high speed cutting or grinding. This paper describes a design process of an active magnetic bearing system for a high speed grinding spindle with power 5.5kW and maximum speed 60,000rpm. Magnetic actuators are designed by the magnetic circuit theory considering static load condition, and examined with FEM analysis. Dynamic characteristics are also considered, such as bandwidth, stiffness, natural frequency and static deflection. System characteristics are simulated with a rigid rotor model.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2002.05a
• /
• pp.46-51
• /
• 2002

A grinding technology is very essential to finish the surface of IT and BT industrial application parts such as wafer, optical connection part and lenses etc. However the finding machine has bead depended on imports. Especially, it is completely imported for machining high precision part relevant to domestic electric and communicational industries. The amount to import grinding machine is about $110milions. It takes about 35% of total import amount of all the machine tools. A domestic finder manufacturer is a very small-scaled bussinessman and research facilities is poor. Recently, it is increasing to demand high speed and precision grinding technology because it brings cost down and value added up. Its further study will be something related to inteligent grinding system fur value added and high precision part. It will make domestic grinding technology to its advanced country level.

• Journal of the Korean Society for Precision Engineering
• /
• v.13 no.5
• /
• pp.115-121
• /
• 1996

Recently, the Z-Map model has been used widely to represent the three dimensional geometric shape and to achieve the cross-section and point evaluation of the shape. In this paper, the CNC cutting planning and simulation modules for product with three dimensional geometric shape are realized based on the Z-Map model. The realized system has the various capabilities related to the automatic generation of tool path for the rough and finish cutting processes, the automatic elimination of overcut, the automatic generation of CNC program for a machining center and the cutting simulation. Especially, the overcut-free tool path is obtained by using the CL Z-Map models which are composed of the offset surfaces of the geometric shape of product.

• Journal of the Korean Society for Precision Engineering
• /
• v.12 no.4
• /
• pp.28-38
• /
• 1995

The flank wear at the minor cutting edge significantly affects the geometric accuracy and surface roughness in finish machining. A fuzzy estimator based on a fuzzy inference algorithm with a max-min composition rule is introduced to evaluate the minor flank wear length. The features sensitive to minor flank wear are extracted from the dispersion analysis of a time series AR model of the feed directional acceleration signal. These features, dispersions, are used for constructing linguistic rules, and then the fuzzy inferences are carried out with test data sets collected under various cutting conditions. The proposed system turns out to be effective for estimating minor flank wear length.

• Journal of the Korean Society for Precision Engineering
• /
• v.12 no.10
• /
• pp.50-56
• /
• 1995

Chatter Vibration is an unwanted phenomenon in metal cutting and it always affects surface finish, tool life, machine life and the productivity of machining process. The real-time detection of the chatter vibration is is necessarily required to automation system. In this study, we constructed the multi-sensing system using Tool Dynamometer, Accelermeter and AE sensor. Especially, Acoustic Emission(AE) generated during turning was investigated the possibility for real-time detection of chatter vibration. Turning experiments were performed using carbide insert tip under realistic cutting conditions and tapered workpiece of SM45C. Consquently, the real-time detection using multi-sensing system can be used for Inprocess monitoring of chatter vibration.

• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.37 no.12
• /
• pp.1159-1165
• /
• 2013

Powder blasting, which is an efficient micromachining method for glass, silicon, and ceramics, has a critical disadvantage in that the surface finish is poor owing to the brittle fracture of materials. Low-pressure waterjet machining can be applied to smoothen the rough surface inside the blasted structure. In this study, the surface roughness and sectional dimension of micro-channels are observed during the repetitive application of a waterjet to blasted micro-channels. The asperities and subsurface cracks created by blasting are removed by waterjet machining. Along with the surface roughness, it is found that the sectional dimension increases and the edges of the finished micro-channel become slightly round. Finally, a microfluidic chip is machined by the blasting-waterjet process and a transparent microfluidic channel is obtained efficiently.

• Journal of the Korean Society for Precision Engineering
• /
• v.21 no.1
• /
• pp.51-60
• /
• 2004

Ball-end milling is one of the most common manufacturing processes for the parts with sculptured surface. However, the conventional roughness model is not suitable for the evaluation of surface texture and roughness under highly efficient machining conditions. Therefore, a different approach is needed for the accurate evaluation of machined surface. In this study, a new method, named ‘Ridge method’, is proposed for the effective prediction of the geometrical roughness and the surface topology in ball-end milling. Theoretical analysis of a machined surface texture was performed considering the actual trochoidal trajectories of cutting edge. The characteristic lines of cut remainder are defined as three-types of ‘Ridges’ and their mathematical equations are derived from the surface generation mechanism of ball-end milling process. The predicted results are compared with the results of conventional method. The agreement between the results predicted by the proposed method and the values calculated by the simulation method shows that the analytic equations presented in this paper are useful for evaluating a geometrical surface roughness of ball -end milling process.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.06a
• /
• pp.90-95
• /
• 2005

To perform the finish outside-diameter grinding process of ferrules which are widely used as fiber optic connectors, a high-precision centerless grinding machine is necessary. In this study, the thermal characteristics of the high-precision centerless grinding machine such as the temperature distribution, temperature rise and thermal deformation, are estimated based on the virtual prototype of the grinding machine and the heat generation rates of heat sources related to the machine operation conditions. The reliability of the predicted results is demonstrated by the temperature characteristics measured from the physical prototype. Especially, the predicted and measured results show the fact that the high-precision centerless grinding machine consisted of the hydrostatic GW and RW spindle systems, hydrostatic RW feeding mechanism, RW swivel mechanism, on-machine GW and RW dressers, and concrete-filled steel bed, has very stable thermal characteristics.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2004.10a
• /
• pp.516-519
• /
• 2004

As the optical communication industry is developed, the demand of optical communication part is increasing. ZrO$_2$ ceramic ferrule is very important part which can determines the transmission efficiency and information quality to connect the optical fibers. In general ZrO$_2$ ceramic ferrule is manufactured by grinding process because the demands precision is very high. And the co-axle grinding process of ZrO$_2$ ceramic ferrule is to make its concentricity all of uniform before centerless grinding. This paper deals with the analysis of the process parameters such as grinding wheel speed, grinding feedrate and regulating wheel speed as influential factors, on the concentricity and surface finish developed based on Taguchi's experimental design methods. Taguchi s tools such as orthogonal array, signal-to-noise ratio, factor effect analysis, etc. have been used for this purpose optimal condition has been found out. Thus, if possible be finding highly efficient and quality grinding conditions.

• Journal of the Korean Society for Precision Engineering
• /
• v.20 no.9
• /
• pp.55-62
• /
• 2003

This paper investigates the micro-cutting of cemented carbides using PCD (polycrystalline diamond) and PCBN (polycrystalline cubic boron nitride) cutting tools are performed with SEM direct observation method. The purpose of this study is to make clear the cutting mechanism of cemented carbides and the fracture of WC particles at the plastic deformation zone in orthogonal micro-cutting. And also to achieve systematic understanding, the effect of machining parameter on chip formation and machined surface was studied, including cutting speed, depth of cut and various tool rake angle. Summary of the results are shown below. (1) Three type of chip formation process have been proposed by the results of the direct observation in orthogonal micro-cutting of cemented carbide materials. (2) From the whole observation of chip formation, primary WC particles are crushed and/or fine grained in the shearing deformation zone. A part of them are observed to collide directly with a cutting edge of tool by following the micro-cutting. (3) Surface finish, surface morphology and surface integrity is good to obtain by cutting with PCD cutting tool compared with PCBN. (4) The machined surface has the best quality near the low cutting speed of 10${\mu}m$/sec with a cutting depth of 10 ${\mu}m$ using 0$^\circ$ rake angle and 3$^\circ$ flank angle in this condition, but it was found that excessively low speed, for example the extent of 1 ${\mu}m$/sec, is not good enough to select for various reason.