• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.1-13
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• 2016

The increase of consumer needs for quality metal cutting related products with more precise tolerances and better product surface roughness has driven the metal cutting industry to continuously improve quality control of metal cutting processes. In this paper, two different approaches are discussed. First, design of experiments (DOE) is used to determine the significant factors and then fuzzy logic approach is presented for the prediction of surface roughness. The data used for the training and checking the fuzzy logic performance is derived from the experiments conducted on a CNC milling machine. In order to obtain better surface roughness, the proper sets of cutting parameters are determined before the process takes place. The factors considered for DOE in the experiment were the depth of cut, feed rate per tooth, cutting speed, tool nose radius, the use of cutting fluid and the three components of the cutting force. Finally the significant factors were used as input factors for fuzzy logic mechanism and surface roughness is predicted with empirical formula developed. Test results show good agreement between the actual process output and the predicted surface roughness.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.1
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• pp.28-37
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• 2004

An on-line monitoring system of endmill failure such as weal, chipping, and fracture is developed using AE, cutting force Characteristic variations of AE and cutting force signals due to endmill failure are identified as follows. When endmill fracture occurs, AE count rate shows a rapid Increase in conjunction with a subsequent decrease while a standard deviation of the principal cutting force Increases significantly. The increase of AE count rate precedes the Increase of standard deviation of principal cutting force. Chipping results in relatively small increase and decrease of AE count rate without any significant variation of the cutting force Gradual increase of AE count rate and mean principal cutting force are Identified to be related with the wear of cutter. A cutter fracture detection algorithm is developed based on the present results. The signals me normalized to enhance the applicability of the algorithm to Wide those of fresh cutters, and qualitative characteristics of AE signals encountered at the moment of fracture are employed. It is demonstrated that the algorithm can detect the cutter fracture successfully.

• 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.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.5
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• pp.77-83
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• 2007

The study on damaged layer is necessary for machinability improvement in micro machining. The damaged layer in metal cutting is derived from plastic deformation and transformation of metal structure. The damaged layer affects micro mold life and micro machine parts. In this study, the damaged layer of micro machined surface of copper is evaluated according to various machining condition. The damaged layer structure and metallurgical characteristics are measured by optical microscope, and evaluated by cutting forces and surface roughness. The scale of this damaged layer depends on cutting process parameters and machining environments. By experimental results, depth of damaged layer was increased with increasing of cutting depth, also the damaged layer is less occurred in down-milling compared to up-milling during micro endmilling operation.

• 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.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.239-244
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• 1999

Radial immersion ratio is an important factor to determine the threshold in face milling and should be estimated in process for automatic force regulation. In this paper, presented is a method of on-line estimation of radial immersion ratio using cutting force. When a tooth finishes sweeping, sudden drop of cutting forces occurs. These force drops are equal to the cutting forces that act on a single tooth at the swept angle of cut and can be acquired from cutting force signals in feed and cross-feed directions. The ratio of cutting forces in feed and cross-feed directions acting on the single tooth at the swept angle of cut is a function of the swept angle of cut and the ratio of radial to tangential cutting force. In the research, it is found that the ratio of radial to tangential cutting force is not affected by cutting conditions and axial rake angle. Therefore, the ratio of radial to tangential cutting force determined by just one preliminary experiment can be used regardless of the cutting conditions. Using the measured cutting forces and predetermined ratio, the redial immersion ratio is estimated. various experiments show that the radial immersion ratio can be estimated by the proposed method very well.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.2
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• pp.199-205
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• 2001

Burr makes troubles on manufacturing process due to deburring cost, quality of products and productivity. This paper described the results of experimental study on the influence of the cutting parameters on the formation of exit burrs in face milling. Using the results of experimental study, burr types are classified and data bases are developed to predict burr formation result. From the CAD file for work geometry and the NC data for tool path, the exit angles are calculated at every edges. This program predicts the burr geometry at exit edges using the prediction algorithm and data bases which are developed experimentally. Simulation results on deformation strain and temperature are also available in specific 2-dimensional cutting conditions. Also algorithm which can determine the exit angle is proposed.

• Korean Journal of Materials Research
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• v.10 no.8
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• pp.532-539
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• 2000

Co-0.5C-(15~20)Cr-20Ni-8W-(2~7)Fe alloy bond in diamond-impregnated abrasive tool was synthesized by ball-milling and mechanical alloying process. When the powders were mechanical alloyed for 6h, micro-welding in most metal powders was observed irrespective of addition of stearic acid. Without stearic acid in metal powders, partial-ly coarse powders were obtained, which could be unfaverable to the densification of composite of composite powders. The hot-pressed compacts showed rupture strength of 1100MPa and hardness of about $46H_{RC}$, respectively.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.2
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• pp.73-78
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• 2011

The existent cutting insert have occupied most product of grinding style, because it has a problem of accuracy and manufacturing process. The product has a concept but development is difficult, because grinding and manufacturing by press are impossible. But by development and stabilization of a technology, preference of non-ground insert increases gradually. And then insert that grinding is impossible is developed availably as non-ground product by using developed equipment and software. In this paper reports some experimental results on the machining performance of non-ground Cutting inserts. Three kinds of Cutting inserts were manufactured without using grinding process. Machining experiments were carried out to compare the machining performance of non-ground inserts with that of ground ones. The experimental results indicate that the cutting forces and tool wear and surface roughnesses of machined surface of both ground and non-ground inserts are comparable.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.7
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• pp.98-104
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• 2022

Circular sawing and milling are general machining processes used for routing fiber-reinforced plastics (FRP). In this study, the productivity and cutting quality of a circular saw and flat endmill were compared. As a result, the productivity of the circular saw was approximately ten times higher than that of the endmill for the same tool life, and the burr size of the circular saw was 14 times smaller than that of the flat-end mill. The spectrogram analysis of the cutting sound also showed that the acoustic emission of the circular saw was more uniform than that of the flat end mill. Circular sawing is thus a more suitable process for the straight cutting of pultrusion FRP than a flat endmill.