• Journal of the Korean Society for Heat Treatment
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• v.29 no.2
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• pp.51-55
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• 2016

The P/M processing of titanium aluminide using amorphous TiAl is developed by which it is possible to overcome inherent fabricability problems and to obtain a fine microstructure. A high quality amorphous TiAl powder produced by reaction ball milling shows clear glass transition far below a temperature at the onset of crystallization in differential scanning calorimetry above a heating rate of 0.05 K/s. We obtained a fully dense compact of amorphous TiAl powders, encapsulated in a vacuumed can, via viscous flow by hot isostatic pressing (HIP). Isothermally annealing of HIP'ed amorphous compact under a pressure of 196 MPa shows a progressive growth of ${\gamma}-TiAl$ phase with ${\alpha}2$ ($Ti_3Al$), which is characterized by increasing sharpness of X-ray peaks with temperature. Fully dense HIP'ed compact of titanium aluminide TiAl shows a high hardness of 505 Hv, suggesting strengthening mechanisms by sub-micron sized grain of ${\gamma}-TiAl$ and particle-dispersion by second phase constituent, ${\alpha}2$.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.993-996
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• 2005

High speed machining(HSM) technique is widely used in the appliance, automobile part and mold industries, which has many advantages such as good quality, low cost and rapid machining time. but it also has problems like tool break, smooth tool path, and so on. In particular, small size end mill is easy to break, so it must be changed before interrupting operation. Generally, the tool life of small size end mill is effected by the milling conditions whose evaluated parameters are spindle, feedrate, and width of cut. The experiments are carried out by full factorial design of experiments using and orthogonal array. This paper shows optimal combination and mathematical model for tool life, and the analysis of variance(ANOVA) is employed to analyze the main effects and the interactions of these milling parameters and the second-order polynomial regression model with three independent variables is estimated to predict tool life by multiple regression analysis.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.151-156
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• 1995

This paper presents a methodology for real-time detecting and identifying the runout geometry of an end mill. Cutter runout is a common but undesirable phenomenon in multi-tooth machining such as end-milling process because it introduces variable chip loading to insert which results in a accelerated tool wear,amplification of force variation and hence enlargement vibration amplitude. Form understanding of chip load change kinematics, the analytical sutting force model was formulated as the angular domain convolution of three dynamic cutting force component functions. By virtue of the convolution integration property, the frequency domain expression of the total cutting forces can be given as the algebraic multiplication of the Fourier transforms of the local cutting forces and the chip width density of the cutter. Experimental study are presented to validata the analytical model. This study provides the in-process monitoring and compensation of dynamic cutter runout to improve machining tolerance tolerance and surface quality for industriql application.

• Journal of Powder Materials
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• v.23 no.3
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• pp.202-206
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• 2016

A Ni-Ti-B alloy powder prepared by mechanical alloying (MA) of individual Ni, Ti, and B components is examined with the aim of elucidating the phase transitions and crystallization during heat treatment. Ti and B atoms penetrating into the Ni lattice result in a Ni (Ti, B) solid solution and an amorphous phase. Differential thermal analysis (DTA) reveals peaks related to the decomposition of the metastable Ni (Ti, B) solid solution and the separation of equilibrium $Ni_3Ti$, $TiB_2$, and ${\tau}-Ni_20Ti_3B_6$ phases. The exothermal effects in the DTA curves move to lower temperatures with increasing milling time. The formation of a $TiB_2$ phase by annealing indicates that the mechanochemical reaction of the Ni-Ti-B alloy does not comply with the alloy composition in the ternary phase diagram, and Ti-B bonds are found to be more preferable than Ni-B bonds.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.1
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• pp.7-14
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• 2004

Machining error is defined the normal distance between designed surface and actual tool path with tool deflection. This is inevitably caused by the tool deflection, tool wear, thermal effect and machine tool errors and so on. Among these factors, tool deflection is usually known as the most significant factor of machining error. Tool deflection problem is analyzed using Instantaneous horizontal cutting forces. The high quality and precision of machining products are required in finishing. In order to achieve these purposes, it is necessary work that decrease the machining error. This paper presents a study on the machining error caused by the tool deflection in ball end milling of 2 dimensional surface. Tool deflection model and simple machining error prediction model are described. This model is checked the validity with machining experiments of 2 dimensional surface. These results may be used to decrease machining error and tool path decision.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1885-1888
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• 2003

As high technology industries such as IT and display have developed, demand for application parts of micro lens and lens array has been extremely increasing. According to these trends, many researchers are studying on the fabrication technology for parts of the micro lens by a variety of methods such as MEMS, Lithography, LIGA and so on. In this paper, we have performed researches related to ultra precision micro lens, lens array mold and fabrication of Lenticular lens mold for three-dimensional display by using mechanical micro end-milling and fly-cutting fabrication method. Tools used in this research were a diamond tool of R 150$\mu\textrm{m}$. Cutting conditions set up feed rate, spindle revolution. depth of cut and dwell time as variables. And we analyzed surface quality variation of the processed products according to the cutting conditions, and then carried out experiments to search the optimum conditions. Through this research, we have confirmed that we can fabricate the ultra precision micro lens mold with surface roughness Ra=20nm and the holographic lens mold by using micro end-milling and fly-cutting fabrication method. Furthermore, we demonstrated problems happened in the fabrication of the micro lens and established the foundation of experimental study for formulating its improvement plan.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.3
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• pp.211-216
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• 2016

Al alloys are useful materials having high specific strength and are used in machining of parts having thin-walled structures for weight reduction in aircraft, automobiles, and portable devices. In machining of thin-walled structures, it is difficult to maintain dimensional accuracy because machining deformation occurs because of cutting forces and heat in the cutting zone. Thus, cutting conditions and methods need to be investigated and cutting signals need to be analyzed to diagnose and minimize machining deformation and thereby enhance machining quality. In this study, an investigation on cutting conditions to minimize machining deformation and an analysis on characteristics of cutting signals when machining deformation occurs are conducted. Cutting signals for the process are acquired by using an accelerometer and acoustic emission (AE) sensor. Signal characteristics according to the cutting conditions and the relation between machining deformation and cutting signals are analyzed.

• Korean Journal of Computational Design and Engineering
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• v.5 no.4
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• pp.347-358
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• 2000

The view dependency of typical spatial-partitioning based NC simulation methods is overcome by polygon rendering technique that generates polygons to represent the workpiece, thus enabling dynamic viewing transformations without reconstruction of the entire data structure. However, the polygon rendering technique still has difficulty in realizing real-time simulation due to unsatisfactory performance of current graphics devices. Therefore, it is necessary to develop a mesh decimation method that enables rapid rendering without loss of display quality. In this paper. we proposed a new mesh decimation algorithm thor a workpiece whose shape varies dynamically. In this algorithm, the 2-map data thor a given workpiece is divided into several regions, and a triangular mesh is constructed for each region first. Then, if any region it cut by the tool, its mesh is regenerated and decimated again. Since the range of mesh decimation is confined to a few regions, the reduced polygons for rendering can be obtained rapidly. Our method enables the polygon-rendering based NC simulation to be applied to the computers equipped with a wider range of graphics cards.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.3
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• pp.24-31
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• 2004

A successful on-line monitoring system for conventional machining operations has the potential to reduce cost, guarantee consistency of product quality, improve productivity and provide a safer environment for the operator. In fine-shape machining, typical signs of tool problems such as vibration, noise, chip flow characteristics and visual signs are almost unnoticeable without the use of special equipment. These characteristics increase the importance of automatic monitoring in fine-shape machining, however, sensing and interpretation of signals ar more complex. In addition, the shafts of the mini-tools break before the typical extensive cutting edge of the tool gets damaged. In this study, the existence of a relationship between the characteristics of the cutting force and tool usage was investigated, and tool breakage detection algorithm by LabVIEW was developed and the following results are obtained. It was possible to use a relative error compare which mainly used in established experiment and investigated tool breakage detection algorithm in time domain which can detect AE and cutting force signals more effective and accurate.

• Korean Journal of Computational Design and Engineering
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• v.9 no.1
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• pp.35-43
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• 2004

It is well known that the five-axis machining has advantages of tool accessibility and machined surface quality when compared with conventional three-axis machining. Traditional researches on the five-axis tool-path generation have addressed interferences such as cutter gouging, collision, machine kinematics and optimization of a CL(cutter location) or a cutter position. In the paper it is presented that optimal CL data for a face-milling cutter moving on a tool-path are obtained by incorporating TSS(tool swept surface) model. The TSS model from current CL position to the next CL position is constructed based on machine kinematics as well as cutter geometry, with which the deviation from the design surface can be computed. Then the next CC(cutter-contact) point should be adjusted such that the deviation conforms to given machining tolerance value. The proposed algorithm was implemented and applied to a marine propeller machining, which proved effective from a quantitative point of view. In addition, the algorithm using the TSS can also be applied to avoid cutter convex interferences in general three-axis NC machining.