• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2000년도 추계학술대회논문집 - 한국공작기계학회
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• pp.274-278
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• 2000

Ball end milling process is widely used in the die and mould manufacturing because of suitableness for the machining of free form surface. But, as ball end mill is long and thin, it is easily deflected by cutting force. In this study, Cutting force, tool deflection and surface precision was measured according to the change of depth and cutting location. Cutting force was acquired with tool dynamometer and a couple of eddy-current sensor measured tool deflection in x-y direction each. After machining, surface precision was measured with roundness tester and coordination measuring machine for sculptured surface angle change and cutting depth.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.410-413
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• 2005

There are technical requirements to manufacture large size functional parts with not only simple geometries like a flat or spherical surface but also sculptured geometries. In addition, the required machining accuracy for these parts is becoming more severe day-by-day. In general, the forms of machined parts are determined by relative position between the workpiece and the tool during cutting. To improve machining accuracy, the relative position error should be maintained within the required accuracy. This study deals with estimation and calibration of depth of cut using AE signal in micro-machining.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2002년도 제5회 압출 및 인발가공 심포지엄
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• pp.79-87
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• 2002

An attempt to automate the surface finishing process of the die and mould has been carried out. An UMB(Ultrasonic Micro Burnishing) equipment which brought the micro plastic cold deformation to the 3D sculptured surface of mold and dies by ultrasonic vibration and static load, was developed and installed at the head stock of a vertical machining center. To be satisfied with the required surface roughness and hardness, the DB based program was also developed and applied. This equipment composes of UMB equipement, CNC vertical machining center, CAD/CAM system and the DB based program fer optimal condition. UMB processing effect was obtained from initial value Ral.25 and Hk337 to Ra0.085 and Hk521 and similar result was shown in industrial mould application.

• 대한산업공학회지
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• 제19권3호
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• pp.139-154
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• 1993

Cutter Interference(or part surface gouging) is one of the most critical problems in NC machining of sculptured surfaces. Presented in this paper is and algorithmic procedure that converts CC data obtained from a compound surface(several surfaces without topological relationship) into interference-free CL data. The interference handling procedure consists of following steps: (1) Z-map model is constructed from input surfaces. (2) Interference sources are detected using local properties of the sources. (3) Interference regions are completely identified based on global tests for neighboring CC points of the interference sources (4) Cutter paths are reconstructed after removing the CC data in interference regions, while avoiding any new interferences.

• 한국정밀공학회지
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• 제18권7호
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• pp.112-119
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• 2001

In modern manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are being designed and produced to meet various sophisticated functional specifications. The cutting force is required not only for the design of machine and cutting tools, but also for the determination of the cutting conditions for the various machining operations. The ball-end mill is deflected by the cutting force and, the tool deflection is one of the main reasons of the machining errors on a free-form surface. Hence, The cutting force generated in the ball-end milling is the most important property of the machining. The purpose of this study is to find the characteristics of the cutting force in inclined plane and the resultant machining errors in the ball-end milling process. Although the depth of cut is constant in the inclined plane, the cutting force area varies due to the hemisphere of the ball-end mill.

• 한국생산제조학회지
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• 제9권2호
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• pp.119-124
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• 2000

In this paper based on geometric optics and geometric modeling aspheric surface of the side mirror mold with dead angle reduced have been designed and machined in a CNC machining center, Surface roughness of the mold was evaluat-ed by usin the surface shaping system. Surface generating simulation of a ball endmill process is investigated. Through the simulation based on the surface-shaping system 3-D engineered surfaces and properties of engineered surfaces are obtained, Computer simulation provides the effective working conditions through the prediction of geometric properties of engineered surfaces. The rear view mirror and room mirror play important role on the safe driving condition as a observation of environment but the rear view mirror can not provide complete information of driving environments due to the existence of the dead angle. The analysis on the shape of formed mirror shows that the proposed me？ improves range of a driver's sight.

• 한국CDE학회논문집
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• 제3권3호
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• pp.161-167
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• 1998

Cutting forces in ball-end milling of slanted surfaces are calculated. The cutting area is determined from the Z-map of the surface geometry and current cutter location. The obtained cutting area is projected onto the cutter plane normal to the Z-axis and compared with cutting edge element location. Cutting force is calculated by integration of elemental cutting forces of engaged cutting edge elements. Experiments with various slanted angles were performed to verify the proposed cutting force estimation model. It is shown that the proposed method predicts cutting force effectively for any geometry including sculptured surfaces with cusp marks and surfaces with pockets and holes.

• 한국정밀공학회지
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• 제11권6호
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• pp.28-41
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• 1994

An efficient algorithm is proposed to select the proper tools and generate their paths for NC rough cutting of dies and molds with sculptured surfaces. Even though a milling process consists of roughing, semi-finishing, and finishing, most material is removed by a rough cutting process. Therfore it can be said that the rough cutting process occupy an important portion of the NC milling process, and accordingly, an efficient rough cutting method contributes to an efficient milling process. In order work, the following basic assumption is accepted for the efficient machining. That is, to machine a region bounded by a profile, larger tools should be used in the far inside and the region adjacent to relatively simple portion of the boundary while smaller tools are used in the regions adjacent to the relatively complex protion. Thus the tools are selected based on the complexity of the boundary profile adjacent to the region to be machined. An index called cutting path ratio is proposed in this work as a measure of the relative complexity of the profile with respect to a tool diameter. Once the tools are selected, their tool paths are calculated starting from the largest to the smallest tool.

• 한국정밀공학회지
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• 제21권1호
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• pp.51-60
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• 2004

Ball-end milling is one of the most common manufacturing processes for the parts with sculptured surface. However, the conventional roughness model is not suitable for the evaluation of surface texture and roughness under highly efficient machining conditions. Therefore, a different approach is needed for the accurate evaluation of machined surface. In this study, a new method, named ‘Ridge method’, is proposed for the effective prediction of the geometrical roughness and the surface topology in ball-end milling. Theoretical analysis of a machined surface texture was performed considering the actual trochoidal trajectories of cutting edge. The characteristic lines of cut remainder are defined as three-types of ‘Ridges’ and their mathematical equations are derived from the surface generation mechanism of ball-end milling process. The predicted results are compared with the results of conventional method. The agreement between the results predicted by the proposed method and the values calculated by the simulation method shows that the analytic equations presented in this paper are useful for evaluating a geometrical surface roughness of ball -end milling process.

• 한국산업정보학회논문지
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• 제9권1호
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• pp.7-16
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• 2004

효율적인 최종 NC코드를 만들어내기 위해서 공구경로는 효과적인 방법으로 결정되어 져야한다. 이는 3축 CNC 공작기계상에서 자유형상의 벽을 가진 자유곡면을 가공할 때 특히 중요하다. 많은 CAD/CAM 시스템들은 자유곡면가공을 위한 NC코드 생성 시 직선 보간을 이용한다. 그러나 이 방법은 가공된 바닥 표면의 매끄러움과 가공시간, 그리고 CL파일 사이즈를 줄이기 위해서 보정되어야 한다. 곡선 가공이 이러한 문제들을 줄이기 위한 해결책이 될 수 있다. 단일화된 황삭과 정삭 알고리즘과 공구경로가 그래픽으로 시뮬레이션 되었다. 본 연구에서는 자유곡면 바닥을 가진 파켓을 3축 CNC 공작기계를 이용하여 일반적인 파켓 밀링을 위한 직선 보간과 직선+아크를 혼합한 보간을 위한 NC 공구경로 데이터를 만들기 위한 3D 격자 항행 알고리즘을 개발하였다.