• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.20 no.2
• /
• pp.38-44
• /
• 2021

To cater to the transition from single-color to multicolor/multi-material printing, this paper proposes a cartridge-replacing type multi-nozzle Fused Depositon Modeling(FDM) three-dimensional (3D) printer. In the test printing run, tool change failure/wobble/layer shift occurred. It was confirmed that improper support was the cause of this tool change failure. As a solution, spline and electromagnetic cartridges were designed. Wobble was caused by machine vibration and the motor stepping out. To minimize wobble, an additional Z-axis was installed, and the four-point bed leveling method was used instead of the three-point bed leveling method. The occurrence of layer shift was ascribed to the eccentricity of the Z-axis lead screw. Therefore, slit coupler was replaced with an Oldham type. In addition to the mechanical supplementation, the control environment was integrated to prevent accidents and signal errors due to wire connections. Before the final test printing run, a rectifier circuit was added to the motor to secure precise control stability. The final test printing run confirmed that the wobble/layer shift phenomenon was minimized, and the maximum error between layers was reduced to 0.05.

• Structural Engineering and Mechanics
• /
• v.52 no.4
• /
• pp.663-686
• /
• 2014

This paper deals with free vibration analysis of bidirectional functionally graded annular plates resting on a two-parameter elastic foundation. The formulations are based on the three-dimensional elasticity theory. This study presents a novel 2-D six-parameter power-law distribution for ceramic volume fraction of 2-D functionally graded materials that gives designers a powerful tool for flexible designing of structures under multi-functional requirements. Various material profiles along the thickness and in the in-plane directions are illustrated by using the 2-D power-law distribution. The effective material properties at a point are determined in terms of the local volume fractions and the material properties by the Mori-Tanaka scheme. The 2-D differential quadrature method as an efficient and accurate numerical tool is used to discretize the governing equations and to implement the boundary conditions. The fast rate of convergence of the method is shown and the results are compared against existing results in literature. Some new results for natural frequencies of the plates are prepared, which include the effects of elastic coefficients of foundation, boundary conditions, material and geometrical parameters. The interesting results indicate that a graded ceramic volume fraction in two directions has a higher capability to reduce the natural frequency than conventional 1-D functionally graded materials.

• Transactions of Materials Processing
• /
• v.17 no.4
• /
• pp.249-256
• /
• 2008

Combined phase transformation and heat transfer was considered on the simulation of hot press forming process, using material properties modeler, $JMatPro^{(R)}$ and a finite element package, $DEFORM^{TM}$-HT. In order to obtain high temperature mechanical properties and flow curves for different phases, a material properties modeler, $JMatPro^{(R)}$ was used, avoiding expensive and extensive high temperature materials tests. The results successfully show that the strength of hot press forming parts may exhibit different strength in the same parts, depending on the contact of blank with tooling. It was also shown effectively that the strength of the parts can be controlled by designing appropriate cooling paths and coolants. This was shown in terms of different heat convection coefficient in the calculation. Overall, current combination of software was shown to be an effective tool for the tool and process design of hot forming process, although the material modeler needs to be additionally verified by an appropriate set of high temperature materials test.

• Journal of Korean Institute of Industrial Engineers
• /
• v.21 no.1
• /
• pp.119-135
• /
• 1995

We consider problems of tool loading and scheduling in a flexible manufacturing system (FMS) in which tool transportation constitutes the major portion of material flows. In this type of FMSs, parts are initially assigned to machines and released to the machines according to input sequencing rules. Operations for the parts released to the machines are performed by tools initially loaded onto the machines or provided by an automatic tool transport robot when needed. For an efficient operation of such systems, therefore, we may have to consider loading and scheduling problems for tools in addition to those for parts. In this paper, we consider three problems, part loading, tool loading, and tool scheduling problems with the overall objective of minimizing the makespan. The part loading problem is solved by a method similar to that for the bin packing problem and then a heuristic based on the frequency of tool usage is applied for tool loading. Also suggested are part input sequencing and tool scheduling rules. To show the effectiveness of the overall algorithm suggested here, we compare it with an existing algorithm through a series of computational tests on randomly generated test problems.

• Design & Manufacturing
• /
• v.14 no.4
• /
• pp.46-51
• /
• 2020

The purpose of this study was to analyze the change in tensile strength characteristics of the weld when the welding speed and rotational speed of the tool, which are representative variables of the friction stir welding process. The equipment used in the experiment was Machining Center No. 5. The material used in the experiment is an AA6061-T6 alloy, and a rolled plate with a thickness of 2mm was used. Two experimental variables were selected, the welding speed of the tool and the rotational speed of the tool. The experimental conditions were selected in the range in which a healthy weld could be obtained through a preliminary experiment. The welding speed of the tool was increased to 100mm/min, 200mm/min, and 300mm/min, and the rotational speed of the tool was increased to 1000rpm, 2000rpm, and 3000rpm. As a result of the experiment, the tensile strength increased as the rotational speed of the tool changed at each tool welding speed. In addition, as the welding speed of the tool increased, the tensile strength of the weld was increased. The condition with the highest tensile strength of the weld was found to be a tool feed speed of 300 mm/min and a tool rotation speed of 3000rpm.

• Design & Manufacturing
• /
• v.18 no.2
• /
• pp.51-56
• /
• 2024

In this study, a tool was developed for analyzing production lead time in turning operations. It is expected to help to reduce machining time and to identify, for example, tool change intervals. The tool was developed using Visual Basic.Net and features a user-friendly graphical user interface (GUI) that allows users to easily input cutting conditions and calculate the usage time and feeding distance for each cutting tool based on a G-code program. Object-oriented programming techniques were also used to encapsulate and classify complex logic, thereby efficiently organizing and managing the functions and data structures of this analysis tool. The analysis tool provides various outputs. It calculates the use time of each detailed process of the turning operation, the use time of each tool, the use time of each type of feeding, and also generates the data needed for cutting time analysis, which can be visualized in charts. The analysis tool developed in this study is expected to significantly contribute to improving the efficiency of manufacturing processes and increasing productivity, particularly, in the manufacturing of components requiring massive material removal, such as aircraft parts.

• Korean Journal of Materials Research
• /
• v.18 no.12
• /
• pp.635-639
• /
• 2008

In this paper, experimental studies of the regrinding of tungsten carbide (WC-Co) tools for high-speed machining were conducted. Regrinding and a subsequent evaluation test were carried out for a flat endmill tool with diameters of 10 mm and 3 mm using a CNC five-axis tool grinder and a CNC three-axis machining center. Tool wear on the two types of endmill tools increased as the cutting length increased, and the tool wear was not influenced by the regrinding state. In case of the micro endmill with a tool diameter of 3 mm, the effective regrinding time was determined for a flank wear threshold of 0.3 mm considering the tool life according to cutting length. The tool lives of the 10 mm and 3 mm endmill tools were increased by 80% and 72%, respectively. This conclusion proves the Feasibility of the recycling of tungsten carbide materials in the high-speed machining of high-hardened materials for industrial applications.

• Journal of the Korean Society for Precision Engineering
• /
• v.19 no.10
• /
• pp.92-98
• /
• 2002

End mill is an essential tool to generate complex surface in workpiece and it has been developed with various materials and tool shapes. The most important factor to evaluate the performance of end mill is still the wear characteristics of flank face. In addition to the flank wear, the tool edge roughness generated by the chipping is another important factor in aspects of material property and machinability evaluation and affects the quality of machined surface. Up to now, there is no direct method for measurement of tool edge roughness. In this study, the tool edge roughness of flat end mill is indirectly measured along the axial direction of workpiece. The theoretical equation is derived in consideration of tool geometry. Finally, the optimal conditions to measure the tool edge roughness by the proposed method are presented through the theoretical review and experimental identification.

• Journal of the Korean Society for Precision Engineering
• /
• v.25 no.12
• /
• pp.47-54
• /
• 2008

Hard turning process can be defined as a single-point machining process carried out on "hard" materials. The process is intended to replace or limit traditional grinding operations that are expensive, environmentally unfriendly, and inflexible. The purpose of this study is to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, tool wear shape and chip formation by the outer cutting of a kind of wear resistant tungsten carbide V30. Hard turning experiments were carried out on this alloy using the PCD (Poly Crystalline Diamond), cBN (cubic Boron Nitride) and PcBN (Polycrystalline cubic Boron Nitride) cutting tools. The PcBN and the usual cBN tools were used to be compare with the PCD tool and the dry turning was carried out. The PcBN is attractive as the tool material which replaces the PCD. The tool wear width and cutting force were measured, and the worn tool and chip were observed. The difference of the tool wear mechanism among the three tool materials was investigated.

• Journal of the Korean Society for Precision Engineering
• /
• v.23 no.7 s.184
• /
• pp.177-186
• /
• 2006

In order to realize a three-dimensional shape on CAD, the machining process has been widely used because it offers practical advantages such as precision and versatility. However, the traditional machining process needs a large amount of time in cutting a product and the remained material causes trouble such as inconvenience due to cleaning process. Therefore, a new rapid manufacturing process, Rapid Heat Ablation process (RHA) using the hot tool, has been developed. In this paper, the hot tool for RHA process is designed to minimize radius of heat affected zone. TRIZ well-known as creative problem solving method is applied to overcome the contradictive requirements of the hot tool. For the detailed design of the hot tool, numerical model is established with several assumptions. In order to verify the numerical results, surface temperature of the hot tool is measured with K-type thermocouple at the predetermined location. Numerical and experimental results show that the devised hot tool fulfils its requirements. The practicality and effectiveness of the designed hot tool have been verified through experiments.