• Title, Summary, Keyword: Cutting tool

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Cutting Performance of TiAlN coated WC Insert Tip (TiAlN을 코팅한 WC공구의 절삭성능에 관한 연구)

  • 김형자;최현철;이규용
    • Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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    • pp.281-286
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    • 2001
  • TiAIN was deposited onto ISO P2O Cutting Insert Tip substrate by FVAS at the substrate temperature of 80$^{\circ}C$. Cutting and wear test have been performed with TiAIN coated and uncoated WC cutting tools, respectively. Uncoated WC cutting tool has been tested under similar cutting condition for comparison. Cutting force and tool wear of coated and uncoated carbide cutting tools were investigated by cutting length. In cutting test, cutting force of the coated insert tip was larger than the uncoated insert tip by tool wear. Configuration and wear of the coated tool were more stable and resistant than the uncoated. In tool life by the tool wear, the coated cutting tool life was rather longer than the uncoated when tested at high speed (V=250 m/min) than low speed (V=200 m/min), Cutting force, tool wear and life were analysised by tool dynamometer amp(3ch) and oscilloscope.

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Closed Form Expression of Cutting Forces and Tool Deflection in End Milling Using Fourier Series (푸리에 급수를 이용한 엔드밀링 절삭력 및 공구변형 표현)

  • Ryu, Shi-Hyoung
    • Journal of the Korean Society for Precision Engineering
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    • v.23 no.9
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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.

Study of the thermal deflection error and the deflection error induced by the cutting force (절삭공구의 열변형 오차 및 절삭력 변형 오차에 관한 연구)

  • Oh, Myung-Seok;Yoon, In-Jun;Baek, Dae-Kyun
    • Journal of the Korean Society of Industry Convergence
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    • v.5 no.4
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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.

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Representation of cutting forces and tool deflection in end milling using Fourier series (엔드밀 가공에서 푸리에 급수를 이용한 절삭력 및 공구변형 표현)

  • Ryu S.H.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.781-785
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    • 2005
  • Cutting forces and tool deflection in end milling are represented as the closed form of tool rotational angle and cutting conditions. The discrete cutting forces caused by tool entry and exit are continued 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 pan are considered for cutting forces and tool deflection estimation. Compared to numerical methods, the presented method has advantages in short prediction time 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 ferm accuracy is easily predicted by tool deflect ion curve.

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Monitoring of Dry Cutting and Applications of Cutting Fluid for Ball End Milling

  • Tangjitsitcharoen, Somkiat;Rungruang, Channarong;Laiaddee, Duangta
    • Industrial Engineering and Management Systems
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    • v.9 no.3
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    • pp.242-250
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    • 2010
  • For economical and environmental reasons, the aim of this research is hence to monitor the cutting conditions with the dry cutting, the wet cutting, and the mist cutting to obtain the proper cutting condition for the plain carbon steel with the ball end milling based on the consideration of the surface roughness of the machined parts, the life of the cutting tools, the use of the cutting fluids, the density of the particles of cutting fluids dispersed in the working area, and the cost of cutting. The experimentally obtained results of the relation between tool wear and surface roughness, the relation between tool wear and cutting force, and the relation between cutting force and surface roughness are correspondent with the same trend. The phenomena of surface roughness and tool wear can be explained by the in-process cutting forces. The models of the tool wear with the cutting conditions and the cutting times are proposed to estimate the tool cost for the different cooling strategies based on the experimental data using the multiple regression technique. The cutting cost is calculated from the costs of cutting tool and cutting fluid. The mist cutting gives the lowest cutting cost as compared to others. The experimentally obtained proper cutting condition is determined based on the experimental results referring to the criteria.

A Study on the Diagnosis of Cutting Tool States Using Cutting Conditions and Cutting Force Parameters(l) - Signal Processing and Feature Extraction - (절삭조건과 절삭력 파라메타를 이용한 공구상태 진단에 관한 연구(I) - 신호처리 및 특징추출 -)

  • Cheong, C.Y.;Yu, K.H.;Suh, N.S.
    • Journal of the Korean Society for Precision Engineering
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    • v.14 no.10
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    • pp.135-140
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    • 1997
  • The detection of cutting tool states in machining is important for the automation. The information of cutting tool states in metal cutting process is uncertain. Hence a industry needs the system which can detect the cutting tool states in real time and control the feed motion. Cutting signal features must be sifted before the classification. In this paper the Fisher's linear discriminant function was applied to the pattern recognition of the cutting tool states successfully. Cutting conditions and cutting force para- meters have shown to be sensitive to tool states, so these cutting conditions and cutting force paramenters can be used as features for tool state detection.

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Characteristics of tool wear in cutting of glass fiber reinforced platics (GFRP) (유리섬유 강화 플라스틱 절삭에서의 공구마멸특성)

  • 이원평
    • Journal of the korean Society of Automotive Engineers
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    • v.9 no.5
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    • pp.49-56
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    • 1987
  • This paper is a study on the effect of the cutting speed on the tool wear in turning of the glass fiber reinforced plastics. The wear behavior of cutting tool is studied by means of turning, changing the cutting speed and feed in the wide range. Moreover, the theoretical model applicable to the cutting speed of wide range is analysed. The main results obtained are as follows: The relation between the tool wear and the cutting speed is divided into three range in case of the constant cutting distance. 1) At the low cutting speed, the tool wear is independent of the cutting speed, but dependent mainly on the contact length between tool and glass fiber(lst range). 2) At the high cutting speed, the tool wear is independent of the contact length, and dependent on the cutting speed only(2nd range). The tool wear increases in proportion to the cutting speed. 3) At the higher cutting speed than the speed in the 2nd range, the tool wear is independent both of the cutting speed and the contact length(3rd range). 4) In the 3rd range, tool flank wear is constant and is observed that only the wear of cutting edge increases.

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A Study on Cutting Toll Damage Detection using Neural Network and Cutting Force Signal (신경망과 절삭력을 이용한 공구이상상태감지에 관한 연구.)

  • 임근영;문상돈;김성일;김태영
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.982-986
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    • 1997
  • A method using cutting force signal and neural network for detection tool damage is proposed. Cutting force signal is gained by tool dynamometer and the signal is prepocessed to normalize. Cutting force signal is changed by tool state. When tool damage is occurred, cutting force signal goes up in comparison with that in normal state. However,the signal goes down in case of catastrophic fracture. These features are memorized in neural network through nomalizing couse. A new nomalizing method is introduced in this paper. Fist, cutting forces are sumed up except data smaller than threshold value, which is the cutting force during non-cutting action. After then, the average value is found by dividing by the number of data. With backpropagation training process, the neural network memorizes the feature difference of cutting force signal between with and without tool damage. As a result, the cutting force can be used in monitoring the condition of cutting tool and neural network can be used to classify the cutting force signal with and without tool damage.

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Determination of Cutting Direction for Tool Path Minimization in Zigzag Milling Operation (Zigzag 밀링가공에서 공구경로 최소화를 위한 가공방향 결정방법)

  • Kim, Byoung-Keuk;Park, Joon-Young
    • Journal of Korean Institute of Industrial Engineers
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    • v.27 no.1
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    • pp.69-88
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    • 2001
  • In the zigzag milling operation, an important issue is to design a machining strategy which minimizes the cutting time. An important variable for minimization of cutting time is the tool path length. The tool path is divided into cutting path and non-cutting path. Cutting path can be subdivided into tool path segment and step-over, and non-cutting path can be regarded as the tool retraction. We propose a new method to determine the cutting direction which minimizes the length of tool path in a convex or concave polygonal shape including islands. For the minimization of tool path length, we consider two factors such as step-over and tool retraction. Step-over is defined as the tool path length which is parallel to the boundary edges for machining area and the tool retraction is a non-cutting path for machining any remaining regions. In the determination of cutting direction, we propose a mathematical model and an algorithm which minimizes tool retraction length in complex shapes. With the proposed methods, we can generate a tool path for the minimization of cutting time in a convex or concave polygonal shapes including islands.

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Generalized Method for Constructing Cutting Force Coefficients Database in End-milling (엔드밀링 가공에서 절삭력 계수 데이터베이스 구현을 위한 일반화된 방법론)

  • 안성호;고정훈;조동우
    • Journal of the Korean Society for Precision Engineering
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    • v.20 no.8
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    • pp.39-46
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    • 2003
  • Productivity and machining performance can be improved by cutting analysis including cutting force prediction, surface error prediction and machining stability evaluation. In order to perform cutting analysis, cutting force coefficients database have to be constructed. Since cutting force coefficients are dependent on cutting condition in the existing research, a large number of calibration tests are needed to obtain cutting force coefficients, which makes it difficult to build the cutting force coefficients database. This paper proposes a generalized method for constructing the cutting force coefficients database us ins cutting-condition-independent coefficients. The tool geometry and workpiece material were considered as important components for database construction. Cutting force coefficients were calculated and analyzed for various helix and rake angles as well as for several workpiece. Furthermore, the variation of cutting force coefficients according to tool wear was analyzed. Tool wear was found to affect tool geometry, which results in the change of cutting force coefficients.