• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2000.04a
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• pp.46-50
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• 2000

The progressive die are multiple operations performed by means of a die having above two stages, on the each of stages performs a different operation as the sheet metal passes through the die hole. In the field of design and making tool for press working, the progressive die for sheet metal (STS 304, thickness : 0.5mm) is a specific division. In order to prevent the defects, the optimum design of the production part, strip layout, die design, die making and tryout etc. are necessary. They require analysis of many kinds of important factors, I. e. theory and practice of metal press working and its phenomena, die structure, machining condition for die making, die materials, heat treatment of die components, know-how and so on. In this study, we designed and constructed a progressive die of multi-stage and performed try out. Out of these processes the die development could be taken for advance. Especially the result of tryout and its analysis become the characteristics of this paper (part 1 and part 2) that nothing might be ever seen before such as this type of research method on all the processes. In the part 1 of this study we treated die design mostly.

• The Bulletin of The Korean Astronomical Society
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• v.42 no.2
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• pp.88.1-88.1
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• 2017

We report a novel design of the "linear astigmatism-free" three mirror system (LAF-TMS). In general, the linear astigmatism is one of the most dominant aberration degrading image qualities in common off-axis systems. The proposed LAF-TMS is based on a confocal off-axis three mirror system, where higher order aberrations are minimized via our numerical optimization. The system comprises three pieces of aluminum-alloy freeform mirrors that are feasible to be fabricated with current single-point diamond turning (SPDT) machining technology. The surface figures, dimensions, and positions of mirrors are carefully optimized for a LAF performance. For higher precision-positioning mechanism, we also included alignment parts: shims (for tilting) and L-brackets (for decentering). Any possible mechanical deformation due to assembly process as well as 1-G gravity, and its influence on optical performances of the system are investigated via the finite element (FE) analysis. The LAF-TMS has low f-number and a wide field of view, which is promising for sky monitoring programs such as supernova surveys.

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.968-973
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• 2003

As environmental restrictions have continuously become more strict, it has emphasized development of environment-friendly technologies. In cutting technology, it has been well recognized that cutting fluids might have undesirable effects on worker's health and working environment and, hence, recently there have been numerous attempts to minimize harmful effects of cutting fluids on environments. To minimize the use of cutting fluids in machining, conventional cutting fluids have been replaced with the technologies of pressurized cold air and minimum quantity lubrication(MQL). Compared with milling, turning is a continuous cutting process, where tools are continuously heated up and lack of lubricity could lead to tool wear and deteriorated surface roughness. In this study, it has been investigated how tool wear and surface roughness could be affected by cutting conditions, supply and cooling methods. The experimental results show that MQL technology is able to minimize harmful effects of conventional cutting fluids.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.999-1002
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• 1997

In this study, in order to set ELID conditions in the internal grinding wheel, the characteristics with the variations of grit size, output voltage and peak current were examined by using conventional machining center(M/C) equipped with electrolytic in-process dressing(EL1D). The initial working voltage was lowered and the working current was high with increasing grit size. The insulating layer thickness increased, as the final voltage increased with the output voltage and peak current. The initial wear rate of the wheel machined with ELID were measured indirectly by using surface roughness tracer. The initial wear rate of the wheel with ELID increased along with high grit size. In case that the grit size with ELID was low, the output voltage and peak current had to be increased to increase the insulating layer thickness. In case of the high grit size, the output voltage and the peak current were established low, which made the insulating layer thickness decreased.

• International Journal of Precision Engineering and Manufacturing
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• v.6 no.3
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• pp.24-28
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• 2005

Stress state of chip formation zone is one of the main problems in metal cutting mechanics. In two-dimensional case this process is usually considered as consistent shears of work material along one of several shear surfaces, separating chip from workpiece. These shear planes are assumed to be trajectories of maximum shear stress forming corresponding slip-line field. This paper suggests a new approach to the constriction of slip-line field, which implies uniform compression in chip formation zone. Based on the given model it has been found that imaginary shear line in orthogonal cutting is close to the trajectory of maximum normal stress and the problem about its determination has been considered as well. It has been shown that there is a second central slip-line field inside chip, which corresponds well to experimental data about stress distribution on tool rake face and tool-chip contact length. The suggested model would be useful in understanding mechanistic problems in machining.

• 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 Precision Engineering Conference
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• 1996.04a
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• pp.39-43
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• 1996

This paper described on the effect of residual stocks in internal grinding of tungsten carbide materials in order to improve the grinding efficiency as well as grinding accuracy. Though the fundamental investigation is carried out for tungsten carbide materials using electroplated diamond wheel, the residual stock after grinding process is effective to the grinding effciiency. The obtained results are as follows: (1) Under the depth of cut(t) is constant and decreasing the workpiece velocity(Vw), the resiudal stock after grinding is increased, but the difference is little less than the difference by table speed. (2) Increasing the wheel velocity, the residual stock after grinding is decreased. Therefore in order to minimize the residual stock, the wheel velocity should be increased as far as possible. (3) The surface foughness and out-of roundness increased with depth of cut and table speed, and decreased with wheel velocity, but it may as well adopt as much as polssible under the dimensional tolerance which is required for high efficiency grinding. (4) In order to remove residual stock, the spark-out grinding shoule be done, and it also can be improved about 20 .approx. 25% throughout spark-out grinding, and the number of optimal spark-out times were within 10 times.

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

• Journal of the Korean Society for Precision Engineering
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• v.33 no.1
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• pp.17-22
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• 2016

In smart factories, the entire manufacturing process from design to the final product is simulated in a virtual manufacturing environment and optimized before starting production. Suppliers and customers make decisions based on the simulation results. Therefore, effective rendering of the information of the virtual products to suppliers and customers is essential for this manufacturing paradigm. In this study, a method of rendering the surface roughness of the virtual products using a tactile display is presented. A tactile display device comprising a $3{\times}3$ array of individually controlled piezoelectric stack actuators is constructed. The surface topology of the virtual products is rendered directly by controlling the piezoelectric stack actuators. A series of experiments is performed to evaluate the performance of the tactile display device. An electrical discharge machined surface is rendered using the proposed method.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.376-381
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• 2003

Ultra precision diamond cutting is a very efficient manufacturing method for optical parts such as HOE, Fresnel lenses, diffraction lenses, and others. During micro cutting, the rake angle is likely to become negative because the tool edge radius is considerably large compared to the sub-micrometer-order depth of cut. Depending on the ratio of the tool edge radius to the depth of cut, different micro-cutting mechanism modes appear. Therefore, the tool edge sharpness is the most important factor affecting the qualities of machined parts. That is why diamond especially mono-crystal diamond, which has the sharpest edge among all other materials is widely used in micro-cutting. The question arises, given a diamond tool, what is the minimum (critical) depth of cut to get continuous chips while in the cutting process\ulcorner In this paper, the micro machinability around the critical depth of cut is investigated in micro grooving with a diamond tool, and introduce the minimizing method of cutting depth using vibration cutting. The experimental results show the characteristics of micro cutting in terms of cutting force ratio (Fx/Fy), chip shape, surface roughness, and surface hardeing around the critical depth of cut.