• Korean Journal of Computational Design and Engineering
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• v.2 no.4
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• pp.253-266
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• 1997

Pencil-curve machining, which is a single-pass ball-end milling along a concave edge on adie surface, is widely employed in die-surface machining. The cutter-path used for pencil-curve machining, which is the trajectory of the “ball-center point” of a ball-endmill sliding along a concave-edge region on the die surface, is called pencil-curve. Presented in the paper is a pencil-curve tracing algorithm in which “concave-type” sharp edges are computed from a “virtually digitized” model of the tool-envelope surface. The resulting “initial” pencil-cures are then refuted by applying a series of fairing operations. illustrative examples and methods for enhancing accuracy are also presented. The proposed pencil-curve tracing algorithm has been successfully implemented in a commercial CAM system specialized in die-machining and in the CAD/CAM system CATIA.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.782-787
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• 1997

This paper proposes methods for pencil machining and uncut area machining. Based on Z-map represented by triangular facets, self-intersection-free offset surface is generated with K-offset method in case of ball mill and flat mill Pencil machining can elliminate overload area before main machining rough, semi-finish and finish cutting,preventing fluctuations of cutting forces in concave regions form causing bad machining condition. Low productivity is caused by uncut area which has excessive or irreguar finishing allowance. Uncut area machining has the finishing allowance keep uniformly on part surface. This paper deals with two types of uncaut area, machining detection of excessive area and user-defined area.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1997.10a
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• pp.88-93
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• 1997

Ball-end milling process is widely used in the die and mold manufacturing because of suitable for the machining of free-form surface. Pencil cutting can eliminate overload in uncut area caused by large diameter of ball-end mill before finish cutting. As the ball-end mill for pencil cutting is long and thin, it is easily deflected by cutting force. The tool deflection when pencil cutting is one of the main reason of the machining errors on a free-from surface. The purpose of the research is to find out the characteristics of deflected cutter trajectory by eddy-current sensor.

• Design & Manufacturing
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• v.7 no.1
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• pp.7-10
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• 2013

Pencil-core dies are relatively new technology in Korea. It is not that no one had tried to make them but had failed due to lack of technologies. However, Posco TMC Co., Ltd, one of the leading die makers in the world, is capable of sophisticated dies including pencil-core dies. Spark plugs made by pencil-core dies have energy efficiency close to 100 percent, which compares to 46 percent of conventional spark plugs. Even though they are now mostly installed in LPG automobiles, more and more diesel and gasoline vehicles are adopting them. This study focuses on how to improve core shape precision using controling design and parts machining methods for pencil-core dies and productivity.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.2 s.95
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• pp.123-129
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• 1999

Ball-end milling process is widely used in the die and mold manufacturing because of suitable one for the machining of free-form surface. During the process, the pencil cutting operation can be adopted before finish cut to eliminate overload in uncut area caused by large diameter of ball-end mill. The ball-end mill cutter for the pencil cutting is easily deflected by cutting force due to the long and thin shape, and the tool deflection in pencil cutting is one of the main reason of the machining errors in a free-form surface. The purpose of this study is to find the characteristics of deflected cutter trajectory by constructing measurement system with eddy-current sensor. It was found that the severe reduction of corner radius produced the overcut during the plane cutting. Up cutting method induced the overcut both plane and slope cutting, but down cutting one induced the undercut. From the experiments, down cutting with upward cutting path can generate the small undercut surface.

• Korean Journal of Computational Design and Engineering
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• v.11 no.1
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• pp.20-26
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• 2006

This paper presents a procedure to compute pencil curves from a triangular mesh which is offset with the radius of a given ball-end mill. An offset triangular mesh has numerous self-intersections caused by an abundance of invalid triangles, which do not contribute to the valid CL-surface. Conceptually, we can obtain valid pencil curves by combining all intersections tying on the outer skin of the offset triangular mesh, i.e., the valid CL-surface. The underlying concept of the proposed algorithm is that visible intersections are always valid for pencil curves, because visible intersections lie on the outer skin of the offset model. To obtain the visibility of intersections efficiently, the proposed algorithm uses a graphics board, which performs hidden surface removal on up to a million polygons per second.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.157-160
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• 1995

Pencil cutting can eliminate overload in uncut area caused by large diameter ball-end mill before finish cutting. As ball-end mill for pencil cutting is long and type, it is easily deflected by cutting force. The tool deflection when pencil cutting with thin and long ball-end mill is one of the main reason of the machining errors on a free-form surface. The purpose of the research is to find the characteristics of deflected cutter trajectory by eddy-current sensor.

• Transactions of the Korean Society of Automotive Engineers
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• v.2 no.5
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• pp.74-84
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• 1994

This paper discusses a method to generate the tool path for NC machining of automobile panel dies. The source data representing a panel die may be generated from digitizing machines, other CAD/CAM systems via IGES files, of compound surface models. From the source data, three types of interferencefree tool paths are generated automatically ; a parallel (Cartesian), an isometric, and a pencil cutting tool path. For the interference-free tool path, a polyhedral model composed of several triangles, and an 'offset triangle' approach are exploited. Finally, some practical examples are illustrated.

• Korean Journal of Computational Design and Engineering
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• v.9 no.3
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• pp.246-252
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• 2004

Presented in this Paper is a Micro Machining Service .(MIMS) based on the World Wide Web technologies. In order to ensure easy access to the service, the web browsers are used as the user interface. The pan geometry as an STL file is uploaded with process parameter for 3-axis CNC milling. Depending on the predefined user level, novice or expert, the user interface requires different parameters for process planning. An STL-based CAM resides in the server and automatically provides NC codes upon user's request. Tool-paths for scanning and pencil-cut, which are interference-free and precise, are created by the curve-based polyhedral machining method. A couple of sample parts were fabricated by a micro endmill with 127 fm diameter. From the tests, the parts fabricated by scanning followed by pencil-cut resulted in less error(within 2%) than the parts machined only by scanning tool-path.