• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 추계학술대회 논문집
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• pp.851-856
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• 1997

This study is on the estimation of the tool temperature for different tool nose radius and cutting conditions in turning. The experiment has been performed in different cutting conditions such as cutting speed, feed rate, and depth of cut for the tool nose radius, 0.4R, 0.8R using SMC workpiece materials. Tool temperature is measured using thermo-couple which is embedded in the insert tip. Using a multiple linear regression method, the tool temperature can be determined as an exponential equation with cutting variables and tool nose diameters for different tool materials. The equations determined in this study show a good correlation for the cutting conditions and can be used for the tool temperature estimation. The result indicates that the tool temperature decreases for ~ncreasing the tool nose radius in general. Also, nose radius hardly influences on the tool temperature compared with cutting speed, feed rate and depth of cut.

• 한국정밀공학회지
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• 제10권2호
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• pp.48-53
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• 1993

At present, the manufacturing industry is in a process of a great change. There is a demand for a variety of types and shorter product life. The change increases the number of different tools and frequencies of tool changes. For the most part, the tools are presetted and offset values are entered manually or via punched tapes to NC machines. Thus a large amount of capital is tied up in the tool area and considerable productive time is lost. Consequently, there is a need for improvement in tool management. This paper describes a computer controlled tool data management system which include: 1) tool identification with bar code. 2) computer aided management and updating of tool data. 3) tool data communication with tool presetter, CNC, etc.

• 한국정밀공학회지
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• 제25권5호
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• pp.60-68
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• 2008

The tool overhang length affects tool deflection and chatter that should be reduced for machined surface quality, productivity and long tool lift. The shortest tool setting algorithm that uses a safe space is proposed and applied with simulation software in NC machining. The safe space in the coordinate fixed in the tool is computed by the virtual machining system that simulates NC machining by stock model, tool model and NC code. The optimal tool assembly that has largest diameter and shortest length is possible using the safe space. This algorithm has been applied over fifty companies for safe and rigid tool setting. The collision accident between holder and stock was reduced from 3 to 0 a year and the productivity was incensed about 15% by using faster feed rate acceptable for shorten tool length.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2004년도 추계학술대회 논문집
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• pp.1066-1069
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• 2004

Recently the monitoring system of tool setup in high speed precision machining tool is required for manufacturing products that have highly complex and small shape, high precision and high function. It is very important to reduce time to setup tool in order to improve the machining precision and productivity and to protect the breakage of cutting tool as the shape of product is smaller and more complex. Generally, the combination of errors that geometrical clamping error of fixing tool at the spindle of machining center and the asynchronized error of driving mechanism causes that the run-out of tool reaches to 3∼20 times of the thickness of cutting chip. And also the run-out is occurred by the misalignment between axis of tool shank and axis of spindle and spindle bearing in high speed rotation. Generally, high speed machining is considered when the rotating speed is more than 8,000 rpm. At that time, the life time of tool is reduced to about 50％ and the roughness of machining surface is worse as the run-out is increased to 10 micron. The life time of tool could be increased by making monitoring of tool-setting easy, quick and precise in high speed machining center. This means the consumption of tool is much more reduced. And also it reduces the manufacturing cost and increases the productivity by reducing the tool-setup time of operator. In this study, in order to establish the concept of tool-setting monitoring the measuring method of the geometrical error of tool system is studied when the spindle is stopped. And also the measuring method of run-out, dynamic error of tool system, is studied when the spindle is rotated in 8,000 ∼ 60,000 rpm. The dynamic phenomena of tool-setup is analyzed by implementing the monitoring system of rotating tool system and the noncontact measuring system of micro displacement in high speed.

• 한국생산제조학회지
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• 제19권6호
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• pp.889-894
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• 2010

Conventional shrink-fit tool holders have positive features, such as high accuracy, high strength, high stiffness and low sensitivity to centrifugal forces, but they require heavy investments for heating and cooling equipment. Generally the heating equipment has to heat the tool holder up to $200{\sim}300^{\circ}C$ for tool changes. This paper introduces a novel shrink-fit tool holder that is able to unclamp a tool at $40{\sim}50^{\circ}C$. This feature makes it possible to switch between the clamped and unclamped states by using a simple device, which has lower power, smaller size and lower cost than the heating equipment of the conventional shrink-fit tool holders. The proposed shrink-fit tool holder is able to expand its tool hole by using the shape memory alloys which are integrated in the tool holder body. Performances of the SMA shrink-fit tool holder were evaluated experimentally. The experimental results confirm that the proposed tool holder is feasible in aspects of clamping/unclamping operations, clamping force and repeatability of tool setup.

• 한국산업융합학회 논문집
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• 제5권4호
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• pp.373-378
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• 2002

This paper presents a method to predict tool deflection induced by the thermal distribution and the cutting force using FEM in milling operation. The thermal distribution of cutting tool was predicted using FEM after measuring the temperature of the end of tool and of the tool holder. The thermal deflection of cutting tool was predicted using FEM as well. The tool deflection induced by the cutting force was analyzed with the solid model of cutting tool. An end mill tool caused most of tool deflection comparing to tool holder. Most of thermal deflection came from Z-direction and most of tool deflection induced by the cutting force came from X and Y direction. Precision cutting will be accomplished when tool locations are generated considering the thermal deflection of cutting tool and the tool deflection induced by the cutting force in CAD/CAM.

• 한국정밀공학회지
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• 제21권1호
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• pp.133-139
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• 2004

High speed machining (HSM) can reduce machining time with the high metal removal rate by high speed spindle and feedrate. This paper supports HSM technology using the small size tool with the optimal tool path generation and modification of tool change. The optimum tool path is generated to reduce cutting length of cavity pattern and change the cutting tool for preventing the tool breakage by wear. The tool path is modified with the experiment data of tool wear and breakage to support tool change on reasonable time. The result can contribute to HSM technology of high hardness materials using the small size end-mill.

• 산업공학
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• 제15권1호
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• pp.64-72
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• 2002

Broaching machine is widely used for machining inner shaped slots in the work-pieces, and provides vertical motion (usually hydraulically powered) between tool and work-piece. In this study, we modelled the tool life process and investigated economic tool life of broaching machine. Tool life process is divided into wear-process and succeeding failure process. Wear process is defined as machining wear and failure process as 'chipping' occurred by random shock. We modelled wear process as linear regression function for products amounts and assumed failure process as Poisson process. Economic tool life is defined as the number of lots which minimizes average tool related cost per lot and analyzed by using age replacement policy technique. As tool-related cost factors, we consider tool replacement cost, tool maintenance cost and quality costs of products. The results of this study can be applied to analyze life process of general machining tools.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 The 8th Asian Symposium on Precision Forging ASPF
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• pp.175-178
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• 2003

Tool life in cold forging is influenced by tool quality as well as forging conditions and quality of forging material. This paper presents some typical examples of tool life improvement in aspect of tool quality depending on tool design and tool manufacturing parameters. For the purpose of improving tool life, suggestions should be based on accurate understanding of tool operating conditions in cold forging process. FE simulation known as CAE is effective in order to make clear the conditions by some numerically calculated result.

• 한국정밀공학회지
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• 제23권9호
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• pp.76-83
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• 2006

Machining accuracy is closely related with tool deflection induced by cutting forces. In this research, cutting forces and tool deflection in end milling are expressed as a closed form of tool rotational angle and cutting conditions. The discrete cutting fores caused by periodic tool entry and exit are represented as a continuous function using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping part are considered together far cutting forces and tool deflection estimation. Compared with numerical methods, the presented method has advantages in prediction time reduction and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the form accuracy is easily predicted from tool deflection curve.