• Journal of the Korean Society for Precision Engineering
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• v.18 no.5
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• pp.130-136
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• 2001

Generally, a metal slitting saw is plain milling cutter with thickness less than 3/16 inch. This is used for cutting a workpiece that high dimensional accuracy and surface finish is necessary. A small thin milling cutter like a metal slitting saw is useful for machining a narrow groove. In this case, built up edge(BUE) is severe at each tooth and affects the surface integrity of the machined surface and tool wear. It is well known that tool geometry and cutting conditions are decisive factors to remove BUE. In this paper, we optimized the geometry of the milling cutter and selected cutting conditions to remove BUE by the experimental investigation. The experiment was planned with Taguchi method based on the orthogonal array of design factors such as coating, rake angle, number of tooth, cutting speed, feed rate. Response table was obtained from the number of built-up edge generated at tooth. The optimized tool geometry and cutting conditions could be determined through response table. In addition, the relative effect of factors was identified bh the analysis of variance (ANOVA). Finally, coating and cutting speed turned out important factors for BUE.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.1
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• pp.49-55
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• 2015

Recently, many researchers and industry are looking for ways to decrease the use of lubricants because of economical and environmental reasons. One of the lubrication technologies is the MQL method. This study presents a research of MQL and Wet milling processes of Al 6061 material. For this experiment, the test specimen is suggested, and various machining conditions are applied. And, shape of micro-pattern which has been recently spotlighted is included in the test specimen. In order to compare MQL with Wet machining, several milling experiments were carried out, varying feed rate, cutting speed, depth of cut, etc. Finally, the surface roughness results of machining tests according to the process conditions were measured. It is expected that the results of machining experiments can be used to predict the surface roughness of various MQL milling processes.

• Journal of Magnetics
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• v.13 no.3
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• pp.102-105
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• 2008

This study examined the feasibility of the combining HDDR-process (hydrogenation, disproportionation, desorption and recombination) with mechanical milling to prepare single domain $Nd_2Fe_{14}B$ particles from a Nd-Fe-B alloy ingot. The $Nd_{15}Fe_{77}B_8$ alloy was HDDR-treated and then subjected to a roller-milling. In the HDDR-treated $Nd_{15}Fe_{77}B_8$ alloy, very small $Nd_2Fe_{14}B$ grains comparable to their critical single domain size(0.3 ${\mu}m$) were observed. These fine individual grains were separated successfully along the grain boundaries by a roller-milling. The separated $Nd_2Fe_{14}B$ grains were found to be single domain particles. These results suggest that single domain particles of the $Nd_2Fe_{14}B$ phase can be prepared from a Nd-Fe-B ingot alloy by combining a HDDR-process with mechanical milling.

• Journal of Powder Materials
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• v.28 no.5
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• pp.403-409
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• 2021

In this study, Ti-Mo-EB composites are prepared by ball milling and spark plasma sintering (SPS) to obtain a low elastic modulus and high strength and to evaluate the microstructure and mechanical properties as a function of the process conditions. As the milling time and sintering temperature increased, Mo, as a β-Ti stabilizing element, diffused, and the microstructure of β-Ti increased. In addition, the size of the observed phase was small, so the modulus and hardness of α-Ti and β-Ti were measured using nanoindentation equipment. In both phases, as the milling time and sintering temperature increased, the modulus of elasticity decreased, and the hardness increased. After 12 h of milling, the specimen sintered at 1000℃ showed the lowest values of modulus of elasticity of 117.52 and 101.46 GPa for α-Ti and β-Ti, respectively, confirming that the values are lower compared to the that in previously reported studies.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.10
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• pp.1493-1498
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• 2010

This paper present the characteristics of micro- and meso-scale milling processes in which compressed cold air, minimum quantity lubrication (MQL) and $MoS_2$ nanofluid MQL are used. For process characterization, the microand meso-scale milling experiments are conducted using desktop meso-scale machine tool system and the surface roughness is measured. The experimental results show that the use of compressed chilly air and nanofluid MQL in the micro- and meso-scale milling processes is effective in improving the surface finish.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.2
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• pp.79-86
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• 2002

In end milling process the undeformed chip thickness and the cutting force components vary periodically with phase change of the tool. In this study, up end milling process is transformed to the equivalent oblique cutting. The varying undeformed chip thickness and the cutting force components in end milling process are replaced with the equivalent average ones. Then it can be possible to analyze the chip-tool friction and shear process in the shear plane of the end milling process by the equivalent oblique cutting system. According to this analysis, when cutting Inconel 718, 61, 64 and 55% of the total energy is consumed in the shear process with the helix angle 30$^{\circ}$, 40$^{\circ}$ and 50$^{\circ}$ respectively, and the balance is consumed in the friction process. With the helix angle of 40$^{\circ}$ the specific cutting energy consumed is smaller than with the helix angle 30$^{\circ}$ and 50$^{\circ}$.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1171-1174
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• 2005

Manufacturing capability at the micro or nano scale production field is requested strongly in view of parts and product miniaturization. Miniaturized parts and products will introduce lots of benefits in terms of high precision functionality and low energy consumption. This paper presents the results of micro milling machine tool development for micro machining process. Finite element analysis has been performed to know the relationship between design dimensional variables and structural stiffness in terms of static, dynamic, thermal aspects. Performance evaluation through machining has been tested and discussed for achievable machining characteristics.

• Journal of Mechanical Science and Technology
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• v.14 no.6
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• pp.622-632
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• 2000

In a high precision vertical machining center, the estimation of cutting forces is important for many reasons such as prediction of chatter vibration, surface roughness and so on. The cutting forces are difficult to predict because they are very complex and time variant. In order to predict the cutting forces of end-milling processes for various cutting conditions, their mathematical model is important and the model is based on chip load, cutting geometry, and the relationship between cutting forces and chip loads. Specific cutting force coefficients of the model have been obtained as interpolation function types by averaging forces of cutting tests. In this paper the coefficients are obtained by neural network and the results of the conventional method and those of the proposed method are compared. The results show that the neural network method gives more correct values than the function type and that in the learning stage as the omitted number of experimental data increase the average errors increase as well.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.8
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• pp.63-70
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• 2002

In end milling process, the undeformed chip section area and cutting forces vary periodically with phase change of the tool. However the real undeformed chip section area deviates from the geometrically ideal one owing to cutter runout and tool shape error. In this study, a method of estimating the real undeformed chip section area which reflects cutter runout and tool shape error was presented in up end milling process using measured cutting forces. The average specific cutting resistance, Ka is defined as the main cutting force component divided by the modified chip section area. Ka value becomes smaller as the helix angle increases from $30^circC \;to\;40\circC$. But it becomes larger as the helix angle increases from $40^\circ$to 50 . On one hand, the Ka value shows a tendency to decrease with increase of the modified chip section area and this tendency becomes distinct with smaller helix angle.

• Transactions of Materials Processing
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• v.22 no.2
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• pp.80-85
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• 2013

The surface integrity of micro-machined products affects the performance of products significantly. Micro-burrs resulting from micro-cutting degrades the surface quality. Therefore it is desired to eliminate them completely and many studies have been undertaken for this purpose. In this study, micro-end-milling was carried out on nickel alloy and brass materials commercially used for light guide plate mold in 3-D optical devices. After completing this micro-machining, the burr heights were measured with a microscope. Then, deburring was done on the machined edges using the MR jet polishing method. A jet angle of $0^{\circ}$ and deburring times of 1, 3, and 5 min. were chosen. It was found that burrs were completely eliminated after 5 min of MR fluid jet polishing.