• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.3
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• pp.225-231
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• 2011

In this paper, a new end-milling force modelling technique was suggested by considering runout, and its result was compared with real measured force. The specific cutting force is the multiplication of cutting force coefficient and uncut chip thickness. This parameter was used for experimental modelling and prediction of theoretical force. These coefficients, which can be obtained by fitting measured average forces in several conditions, were used for the formulation of theoretical force. The mechanism of end-milling force with runout was developed in this research and its result was verified by comparing the fluctuating theoretical force and its measured one. The fluctuation of force was incurred by a geometric shape of workpiece and its runout in holding. The result of suggested force considering runout shows a good consistency with measured one. So this modelling method can be used effectively for a prediction of end-milling force with runout effect.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.4
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• pp.83-91
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• 2006

At present, industry and researchers are looking for ways to reduce the use of lubricants because of ecological and economical reasons. Therefore, metal cutting is to move toward dry cutting or semi-dry cutting. One of the technologies is known as MQL(Minimum Quantity Lubrication) machining. This research presents an investigation into MQL machining with the objective of deriving the optimum cutting conditions for the turning process of SM4SC. To reach these goals several finish turning experiments were carried out, varying cutting speed, feed rate, oil quantity and so on, with MQL and flood coolant. The surface roughness and cutting force results of tests were measured and the effects of cutting conditions were analyzed by the method of Analysis of Variance(ANOVA). From the experimental results and ANOVA, this research proposed optimal cutting conditions to improve the machinability in MQL turning process.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.554-558
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• 2001

In this study, a hybrid method is used to search the pseudo-optimal solution for the I-dimentional nesting problem. This method is composed of the genetic algorithm for the global search and a simple heuristic one for the local search near the pseudo optimal solution. Several simulation results show that the hybrid method gives very satisfactory results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.173-178
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• 1995

This paper presents a new method to obtain parameters of end-mill cutting system. For high speed milling and precision surface finish, we have to predict the deflection of tool and the critical depth of cut. The cutting system can be modeled to a vibratory system to obtain the deflection of tooll and the critical depth of cut. A new method of the modeling of one degree of freedom system was developed using bisection method, ARMA(Autoregressive Moving average) and impact test.

• Journal of Mechanical Science and Technology
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• v.18 no.12
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• pp.2182-2189
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• 2004

In the recent years, environmentally conscious design and manufacturing technologies have attracted considerable attention. The coolants, lubricants, solvents, metallic chips and discarded tools from manufacturing operations will harm our environment and the earth's ecosystem. In the present work, the Tukey method of multiple comparisons is used to select the minimum level of coolant required in a turning process. The amount of coolant is varied in 270 designed experiments and the parameters cutting temperature, surface roughness, and specific cutting energy are carefully evaluated. The effects of coolant mix ratio as well as the amount of coolant on the turning process are studied in the present work. The cutting temperature and surface roughness for different quantity of coolant are investigated by analysis of variance (ANOVA) - test and a multiple comparison method. ANOVA-test results signify that the average tool temperature and surface roughness depend on the amount of coolant. Based on Tukey's Honestly Significant Difference (HSD) method, one of the multiple comparison methods, the minimum level of coolant is 1.0 L/min with 2% mix ratio in the aspect of controlling tool temperature. F-test concludes that the amount of coolant used does not have any significant effect on specific cutting energy. Finally, Tukey method ascertains that 0.5 L/min with 6% mix ratio is the minimum level of coolant required in turning process without any serious degradation of the surface finish. Considering all aspects of cutting, the minimum coolant required is 1.0 L/min with 6% mix ratio. It is merely half the coolant currently used i.e. 2.0 L/min with 10% mix ratio. Minimal use of coolant not only economically desirable for reducing manufacturing cost but also it imparts fewer hazards to human health. Also, sparing use of coolant will eventually transform the turning process into a more environment-conscious manufacturing process.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1998.10a
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• pp.121-124
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• 1998

It is well known that during the oxygen cutting residual thermal stresses are produced in weldment. Surface compressive residual stress is one of reasons for improvement on fatigue durability. To reduce the residual stress and improve the fatigue strength applied the impact loading in oxygen cutting frame. After applying the impact loading, redistribution of residual stress was measured by cutting method and tested fatigue tests.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.3
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• pp.713-723
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• 1995

In intelligent machine tools, a computer based control system, which can adapt the machining parameters in an optimal fashion based on sensor measurements of the machining process, should be incorporated. In this paper, the technology for adaptively optimizing the cutting conditions to maximize the material removal rate in face milling operations is proposed using the exterior penalty function method combined with multilayered neural networks. Two neural networks are introduced ; one for estimating tool were length, the other for mapping input and output relations from experimental data. Then, the optimization of cutting conditions is adaptively implemented using tool were information and predicted process output. The results are demonstrated with respect to each level of machining such as rough, fine and finish cutting.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.3
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• pp.14-21
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• 1998

The in-process detection of the state of cutting tool is one of the most important technical problem in Intelligent Machining System. This paper presents a method of detecting the state of cutting tool in turning process, by using Artificial Neural Network. In order to sense the state of cutting tool. the sensor fusion of an acoustic emission sensor and a force sensor is applied in this paper. It is shown that AErms and three directional dynamic mean cutting forces are sensitive to the tool wear. Therefore the six pattern features that is, the four sensory signal features and two cutting conditions are selected for the monitoring system with Artificial Neural Network. The proposed monitoring system shows a good recogniton rate for the different cutting conditions.

• Korean Journal of Computational Design and Engineering
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• v.3 no.4
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• pp.236-242
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• 1998

This paper presents a development of computer aided cutting tool selection techniques for rough and finish turning operations. The developed system,. which is one of important activities for computer aided operation planning, firstly implements operation sequencing. Then, from relations of the size of machined area, recommended finishing allowance and maximum depth of cut, a main machining method is selected, a number of cut is calculated, cutting tools including toolholders and inserts are selected, and values for cutting parameters are determined. A cutting tool selection procedure is proposed for toolholders and inserts of ISO code in rough cutting, and some important parameters such as holder style, tool approach angle, tool function and its direction are described in detail. In order to demonstrate the validity of the system a case study is performed.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.171-178
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• 2000

In this study, an indirect method to estimate the setup runout of a ball-end mill from cutting force signal is proposed. This runout makes cutting forces of each tooth of the milling cutter unequal. By transforming the cutting force model from time domain to frequency domain through time-convolution theorem, the magnitude and phase angle of runout can be explicitly expressed with material constants, cutting conditions, and force signal. The static setup runout can be obtained by extrapolating estimated effective runout, which is independent of feedrate but decreases linearly with increase in axial depth of cut. The setup runout estimated by slot cutting experiments, shows good agreement with the measured one.