• Journal of the Korean Society for Precision Engineering
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• v.2 no.2
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• pp.69-75
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• 1985

The object of this study is to discuss the effect of cutting fluid on the mechanism of chip formation in orthogonal cutting. Rehbinder effect has been known as a phenomenon, the reduction of mechanical strength, when the metal is exposed in a polar organic environment or the surface of metal is coated with some polar organic substances. About the cause of Rehbinder effect there have been many different ideas by Rehbinder, Merchant, Shaw, Sakakida and etc. In this report, the effects of surface active medium (magic ink) upon the mechanism of chip formation on the orthogonal cutting of copper and the mechanical properties of the work material are experimentally discussed with constant rake angle. Under the condition of polar organic environment the experimental results are as follows; 1) The chip thickness becomes thinner and slip line pitch on the free surface of chip becomes smaller than that of dried cutting area. 2) The order of alternation of cutting ratio was changed. 3) The friction angle on the tool face is not affected by the depth of cut. 4) The cutting force and shear strain on the shear plane decrease remarkably, therefore the work material must be embrittled under polar organic environment.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.1
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• pp.1-15
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• 1998

In this paper, thermo-viscoplastic finite element analysis of the effect of tool edge radius on cutting process are performed. The thermo-viscoplastic cutting model is capable of dealing with free chip geometry and chip-tool contact length. The coupling with thermal effects is also considered. Orthogonal cutting experiments are performed for 0.2% carbon steel with tools having 3 different edge radii and the tool forces are measured. The experimental results are discussed in comparison with the results of the FEM analysis. From the study, we confirm that this cutting model can well be applied to the cutting process considered the tool edge radius and that a major causes of the "size effect" is the tool edge radius. With numerical analysis, the effects of the tool edge radius on the stress distributions in workpiece, the temperature distributions in workpiece and tool, and the chip shape are investigated.estigated.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.5 no.4
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• pp.59-64
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• 2006

High Speed Machining(HSM) reduces machining time and improves surface accuracy because of the high cutting speed and feedrate. Development of HSM makes it allowable to machine difficult-to-cut material and use small-size-endmill. It is however limited to cutting condition and tool material. In the machining operation, it is important to check main parameter of tool life and select optimal cutting condition because tool breakage can interrupt progression of operation. In this study, cutting parameters are determined to 3 factors and 3 levels which are a spindle speed, a feedrate and a width of cut. Experiment is designed to orthogonal array table for L9 with 3 outer array using Taguchi method. Also, it is proposed to inspect significance of the optimal factors and levels by ANOVA using average of SN ratio for tool life. Finally, estimated value of SN ratio in the optimal cutting condition is compared with measured one in the floor shop and reduction of loss is predicted.

• International Journal of Safety
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• v.3 no.1
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• pp.1-5
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• 2004

This study discusses frequency analysis based on autoregressive (AR) time series model, and the characterization of surface quality in orthogonal cutting of a fiber-matrix composite materials. A sparsely distributed idealized composite material, namely a glass reinforced polyester (GFRP) was used as workpiece. Analysis method employs a force sensor and the signals from the sensor are processed using AR time series model. The experimental correlations between the fiber pull-out and AR model coefficients are then established.

• Proceedings of the Korean Institute of Industrial Safety Conference
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• 2000.06a
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• pp.52-57
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• 2000

This paper discusses frequency analysis based on frequency spectrum in orthogonal cutting of fiber-matrix composite materials. A glass reinforced polyester (GFRP) was used as workpiece. Analysis method employs a force sensor and the signals from the sensor are processed using a fast Fourier transform (FFT) technique. The experimental correlation between the different chip formation mechanisms and model coefficients are then established. (omitted)

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.4
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• pp.57-63
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• 2011

The aim of this study is to analyze turning process using commercial FEM simulation code. Various simulation models of orthogonal cutting process for 3 layers of metallic material have been simulated and analyzed. The workpiece material used for the orthogonal plane-strain metal cutting simulation consists of three layers, which are Allow Tool Steel, Aluminum and Stainless Steel. The finite element model is composed of a deformable workpiece and a rigid tool. The tool penetrates through the workpiece at a constant speed and constant feed rate. As an analytical result, detailed cutting temperature, strain, pressure, residual stress for both a tool and each layer of workpiece were obtained during the turning process. It has been closely observed that the chip flow curve deforms continuously.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.265-270
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• 1995

In orthogonal cutting a new approach for modeling of burr formation process when tool exits workpiece is proposed. The approach is based on the rigid-plastic FEM combined with the ductile fracture criterion and the element kill method. The approach is applied to simulate a plane strain cutting process. The results of the FEM are compared with those of the experiment. It is shown that the fracture location and fracture angle as well as cutting force can be predicted using the proposed approach with a good correlation to experimental results.

• Journal of the Korea Safety Management & Science
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• v.3 no.1
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• pp.117-125
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• 2001

Polyacetal resin is usually used to make molds, but it is difficult to achieve dimension accuracy during molding. Therefore it is usually necessary to cut the polyacetal resin after a molding process. Polyacetal resin is easily machining by standard machine tool. Acetal is also a thermal stable material which can be totted without coolant Another concern about the use of polyacetal resin is that it absorbs water easily, which also results in problems with dimension accuracy Therefore, in this study, the cutting resistance of water-absorbed polyacetal resin and its surface roughness after cutting in order to achieve the highest degree of accuracy in the cutting of polyacetal resin were investigated. Also, The Robust Design method uses a mathematical tool called orthogonal arrays to study a large number of decision variables with a small number of experiments. It also uses a new measure of quality, called signal-to-noise (S/N) ratio, to predict the quality from the customer's perspective. Thus, we have taken Taguchi's parameter design approach, specifically orthogonal array, and determined the optimal levels of the selected variables through analysis of the experimental results using S/N ratio.

• Journal of Advanced Marine Engineering and Technology
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• v.19 no.1
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• pp.45-53
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• 1995

Temperature distribution on flank face in orthogonal turning with cutting tool of high speed steel is studied by using a finite element method and experiments. Experiments are carried out to verify the validity of the temperature measurement by using a thermoelectric couple junction imbedded in a cutting tool of high speed steel. Good agreement is obtained between the analytical results and the experimental ones for the temperature distributions on flank face of cutting tool with high speed steel. The analytical results show that the temperature on the top flank face of a tool is higher because of the difference of the friction velocity on each face of the tool.

• Journal of the Korean Society for Precision Engineering
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• v.34 no.4
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• pp.237-241
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• 2017

Cryogenic machining uses liquid nitrogen (LN2) as a coolant. This machining process can reduce the cutting temperature and increase tool life. Titanium alloys have been widely used in the aerospace and automobile industries because of their high strength-to-weight ratio. However, they are difficult to machine because of their poor thermal properties, which reduce tool life. In this study, we applied cryogenic machining to titanium alloys. Orthogonal cutting experiments were performed at a low cutting speed (1.2 - 2.1 m/min) in three cooling conditions: dry, cryogenic, and cryogenic plus heat. Cutting force and friction coefficients were observed to evaluate the machining characteristics for each cooling condition. For the cryogenic condition, cutting force and friction coefficients increased, but decreased for the cryogenic plus heat condition.