• Journal of the Korean Society for Precision Engineering
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• v.25 no.5
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• pp.60-68
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• 2008

The tool overhang length affects tool deflection and chatter that should be reduced for machined surface quality, productivity and long tool lift. The shortest tool setting algorithm that uses a safe space is proposed and applied with simulation software in NC machining. The safe space in the coordinate fixed in the tool is computed by the virtual machining system that simulates NC machining by stock model, tool model and NC code. The optimal tool assembly that has largest diameter and shortest length is possible using the safe space. This algorithm has been applied over fifty companies for safe and rigid tool setting. The collision accident between holder and stock was reduced from 3 to 0 a year and the productivity was incensed about 15% by using faster feed rate acceptable for shorten tool length.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.26-31
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• 1994

The analysis of acoustic emission signals generated during machining has been proposed as a technique for studying both the fundamentals of the cutting process and process and as a methodology for detecting tool fracture on line. In this study, AE signals detected during End Milling were applied as the experimental test to sensing tool fracture on the CNC vertical milling machine. Because automatic monitoring of the cutting condition is one of the most important technologies in machining, the in-process detection of cutting tool life including fracture has been investigated by performing experimental test.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.38-43
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• 1994

In milling process, monitoring and diagosis system is very importent to accomplish factory automation. In this study, to drvelope on-line tool breakage detection system in face milling operation, analysis and experiment were performed. The tool breakage detection experiment was performed in machining center and the effectiveness of the detection tool breakage detection alorithm and the usage of feed drive current as a detection signal were verified.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1816-1819
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• 2003

As a result of milling operation, we expect to have burr at the outward edge of workpiece. Also, it causes undesirable problems such as deburring cost, low quality of machined surface, and bottleneck in manufacturing process. Though it is impossible to totally remove burr in machining, it is necessary to plan a machining process that minimizes the occurrence of burr. In this paper, a scheme is proposed which identifies the tool path of the milling operation with minimum burr. In the previous research, a Burr Expert System was developed where the feature identification, the cutting condition identification, and the analysis on exit burr formation are the key steps in the program. The Burr Expert System predicts which portion of workpiece would have the exit burr in advance so that we can calculate the burr length of each milling operation. Here, the critical angle determines whether the burr analyzed is an exit burr or not. So the burr minimization scheme becomes to minimize the burr with critical angle. By iterating all the possible tool paths in certain milling operation, we can identify the tool path with minimum burr.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.9 s.186
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• pp.76-83
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• 2006

Machining accuracy is closely related with tool deflection induced by cutting forces. In this research, cutting forces and tool deflection in end milling are expressed as a closed form of tool rotational angle and cutting conditions. The discrete cutting fores caused by periodic tool entry and exit are represented as a continuous function using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping part are considered together far cutting forces and tool deflection estimation. Compared with numerical methods, the presented method has advantages in prediction time reduction and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the form accuracy is easily predicted from tool deflection curve.

• Journal of Technologic Dentistry
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• v.41 no.2
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• pp.63-69
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• 2019

Purpose: The purpose of this study is to evaluate the effect of CAD/CAM system milling tool wear on the marginal and internal fit of PMMA implant interim prosthesis three-dimensional manner. Methods: A total of 20 crowns were fabricated with CAD/CAM method. Their designs were unified to first molar of the left maxilla. The Customized abutments were prepared and scanned with on optical model scanner. Five crowns were milled by the newly replaced tool (1st milling), and 15 crowns were milled by 2nd, 3rd, 4th milling tool. The marginal and internal fit of 20 interim crowns were measured using the triple-scan protocol. Results: Statistically significant difference was found between the $1^{st}$ milling group ($51.8{\pm}14.6{\mu}m$) and the $3^{rd}$, $4^{th}$ milling group ($128.6{\pm}43.8{\mu}m$, $146.2{\pm}38.1{\mu}m$, respectively) at the distal margins. In the mesial margins, There was a statistically significant difference between the $1^{st}$ milling group ($63.6{\pm}25.9{\mu}m$) and the $3^{rd}$, $4^{th}$ milling group ($137.2{\pm}25.9{\mu}m$, $186.8{\pm}70.6{\mu}m$, respectively). In the distal line angle, significant difference was found between the $1^{st}$, $2^{nd}$, $3^{rd}$ milling groups and the $4^{th}$ milling group. In the mesial axial wall, significant difference was found between the $1^{st}$ milling group ($52.2{\pm}20.3{\mu}m$) and the $3^{rd}$, $4^{th}$ milling groups ($22.8{\pm}8.8{\mu}m$, $7.8{\pm}5.7{\mu}m$). Conclusion: As a result of the experiment, decrease of the marginal and internal fit was statistically significant as the number of machining cycles increased. In order to produce clinically excellent restorations, it is recommandable to consider the condition of the milling tool wear, when designing the restoration with CAD program.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.4
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• pp.104-111
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• 2008

The objective of this study is to evaluate micro end-milling characteristics and tool wear behavior of AlN-hBN composites. First, AlN based composites with hBN contents in the range of 10 to 20vol% were prepared by hot-pressing. Vickers hardness and flexural strength of the prepared composite specimens were measured and compared according to the vol% of hBN variations. Then, cutting force variations were measured and analyzed using a tool dynamometer during the micro end-milling experiments; and machined surface shapes and roughness were investigated using a 3D non-contact type surface profiler. After micro end-milling, worn tools were investigated using a tool microscope and SEM images. From the experimental results, it can be observed that the cutting forces decreased, and surface qualities were improved with increasing hBN contents. At low content of hBN, tool chipping was observed; and tool wear rate decreased with increasing hBN contents. The results of this study insist that proper machining conditions, including tool wear behavior investigation, should be determined for the micro end-milling of AlN-hBN composites for its further application.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.3
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• pp.76-80
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• 2013

This paper reports some experimental results on the machining performance of ground & non-ground milling inserts. Five kinds of milling inserts were manufactured without grinding process and one milling insert was manufactured with grinding process. Machining experiments were carried out to compare the performance of ground & non-ground inserts. This experimental result indicate that tool wear, cutting force and surface roughness of the each tool. From the result five milling inserts that have non-grinding process and one milling insret that have grinding process compared appear.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.83-88
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• 2001

In order to suggest the proper optimal conditions of the CNC milling machining for the Thin-wall surface, some experiments were carried out. The process was applied in the aerospace industry for the machining of light alloys, notably aluminium. In recent year, however, the mold and die industry has begun to use the technology for the production of components, including those manufactured from hardened tool steels. And the end mill is an important tool in the milling process. A typical example for the end mill is the milling of pocket and slot in which a lot of material is removed from the workpiece. Therefore the proper selection of cutting parameter for end milling is one of the important factors affecting the cutting cost. In this paper, we choose the optimal parameters(cutting forces) to cut thin-walled Al part by experiment.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.95-100
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• 2001

Recently, coated milling cutters are widely used for improving the productivity of cutting processes through high speed cutting and longer tool life. In metal cutting, cutting force increase rate is important factor to diagnose the cutting conditions because the amount of tool wear directly influences the cutting forces. As the cutting length increases, the worn cutter increases the cutting forces. In this study, the effect of coating process of end milling cutter on the cutting performance, especially on the cutting force increase rate, is investigated. The results acquired through the cutting test measuring cutting force increase rate show that not only the injection quantity of $N_2$ and Ar but also mean temperature influence the cutting force increase rate during the end milling process.