• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2008년도 춘계학술대회 논문집
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• pp.513-514
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• 2008

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 춘계학술대회 논문집
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• pp.1003-1008
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• 1997

In this paper, the prediction of cutting force and tool deflection in the ball-end milling process are studied. Identifying various cutting region using Z-map, cutting force in the ball-end milling process can be predicted. Cutting force deflects the tool and the tool deflection changes the cutting force. Tool deflection is included in the cutting force prediction. Tool deflecition also causes machining error of the machined surface. A series of experiments were performed to verify the simulated cutting force and machining error.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 춘계학술대회 논문집
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• pp.890-893
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• 2000

In this paper, the test of machinability according to the cutting positions when the ball end milling of hemispheric workpiece is carried out to find the optimum cutting position of free form surface die. Tool runout, cutting force. and chip form are measured. The results show that the optimum cutting condition to get the constant feed per tooth is the inclined angle of 40 degree of workpiece.

• 산업공학
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• 제8권3호
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• pp.155-169
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• 1995

일반적인 CAD/CAM 시스템을 이용해서 생성한 NC-code는 오류의 가능성의 항시 내포되어 있으므로, 실 가공하기 전에 NC-code의 불량 여부를 검사할 필요가 있다. 본 논문에서는 Z-map 형태의 계산모형을 이용한 모의가공의 계산방법을 볼엔드밀, 평엔드밀, 라운드엔드밀에 대해서 도식적으로 설명하였다. 또, 모의가공 된 형상만으로 NC-code의 불량 여부를 검사하는 자체적인 검사방법과 모의가공 된 형상과 설계형상을 비교해서 불량여부를 판별하는 비교 검사방법을 제시하였다. Z-am 모델을 모의가공과 가공형상의 검증에 사용하면, 빠른 속도로 실제가공 상황을 재현 할 수 있고 육안 검증을 포함한 다양한 수치적 검증이 가능하다. 또, 간단한 데이터 구조이므로 필요한 앨고리즘을 효율적이고, 로버스트하게 구현할 수 있다.

• 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.

• 한국공작기계학회논문집
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• 제15권5호
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• pp.79-84
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• 2006

In modem manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are designed and produced. In the production of these complex-shaped mechanical components, e.g. automobile dies, molds, and various engineering applications, the ball-end milling process is one of the most widely used NC machining processes that consists of roughing, semi-finishing and finishing. In semi-finishing, cusps remained after roughing according to the used tools that have two patterns of stairs and wave shapes. These cusp shapes have air-cut in cutting and instability caused by high cutting speed that affects the cutting characteristics such as cutting force and tool wear. Cutting characteristics are measured and analyzed through cutting force, FFT analysis of cutting force and tool wear along cutting length according to low tool paths with same metal removal rate. As a results of the experiments, this study suggests the optimal conditions of tool path and cutting direction. This approach for the cutting characteristics of semi-finishing provides a useful aid for the productivity and efficiency improvements of NC machining processes.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 춘계학술대회 논문집
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• pp.944-947
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• 2000

Sculptured surface machining plays a vital role in the process of bring new products to the market place. A great variety of products rely on this technology for the production of the dies and moulds used in manufacturing. And, the use of CNC machines and CAD/CAM system has become a vital parts of product development process. The propose of this study is to investigate the effect of cutting parameters on the machinability such as surface roughness and cusp generated in the machining of sculptured surface on a three-axis CNC machining center using the CAD/CAM system. Experimental result showed that: In step down cutting, as the inclined angle of surface became smaller, the cusp height appeared higher. On the other hand, in step over cutting, as the inclined angle of surface became larger, the cusp height appeared higher. In the point of precision machining, step over cutting was more effective. For the minimization of cusp height, step down cutting was effective in larger inclined surface, but step over cutting in smaller inclined surface.

• 한국정밀공학회지
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• 제17권1호
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• pp.171-178
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• 2000

In this study, an indirect method to estimate the setup runout of a ball-end mill from cutting force signal is proposed. This runout makes cutting forces of each tooth of the milling cutter unequal. By transforming the cutting force model from time domain to frequency domain through time-convolution theorem, the magnitude and phase angle of runout can be explicitly expressed with material constants, cutting conditions, and force signal. The static setup runout can be obtained by extrapolating estimated effective runout, which is independent of feedrate but decreases linearly with increase in axial depth of cut. The setup runout estimated by slot cutting experiments, shows good agreement with the measured one.

• 한국기계가공학회지
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• 제13권4호
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• pp.28-35
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• 2014

A composite honeycomb core is widely used for lightweight aircraft materials. However, the composite honeycomb core coupled with metal-cutting machining processes does not make a very good match. This paper describes an experimental study of the shape-machining characteristics of a composite honeycomb core, in which a five-axis gantry machine is used. The experimental conditions of the offset allowance, tooling condition and feed rate were applied. The shape machining characteristics of a flat surface, a vertical surface, and a concave surface are evaluated by comparing the machining shape and burr characteristics.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1991년도 춘계학술대회 논문집
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• pp.284-289
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• 1991

3차원 자유곡면을 볼엔드밀을 사용하여 금형가공을 할 경우, 가공면에는 공구경로에 따른 흔적과 NC공작기계의 직선보간시 발생되는 가공오차에 의하여 공작물 상에 가공오차가 필연적으로 발생되게 된다. 따라서 공작기계상에 서 금형가공을 수행한 후에는 가공오차를 제거하고 금형의 표면을 매끄럽게 하기위하여 연마작업이 픽수적으로 요구 되고있다. 본 연구에서는 3차원 자유곡면으로 이루어진 금형의 연마가공에 로봇을 도입하고, 이를 위한 로봇 작업단의 경로 제어시비전문가라 할지라도 CAM시스템으로 부터 금형 가공용 NC공작기계의 공구경로데이타(Cutter Location Data)를 받으면 자유곡면을 모형화한 후 자유곡면의 법선벡터와 연마로봇 작업단의 위치벡터를 자동으로 생성하고, 그에 따른 로봇의 작업명령을 자동으로 생성할 수 있는 CAMPoli 오프라인 로봇 프로그래밍 시스템을 개발하였다. CAMPoli시스템은 마이크로소프트사의 WINDOWS/386 오퍼레이팅 시스템을 이용하여 IBM-PC/386 상에서 개발되었으며 그주요한 내용들은 다음과 같다. i) CAM시스템으로 부터 입력된 CL-데이타로부터 연마면에 대한 자유곡면을 생성하고, ii) 연마공정의 데이타베이스에 기초한 연마면수의 지정 및 변경을 수행하고, iii) 자유곡면 연마를 위한 로봇 작업단의 위치벡터와 법선벡터를 계산하고, iv) 기존의 로봇언어를 이용한 오프라인 소스프로그램(Source Program)을 생성 및 그래픽 시뮬레이션 하는 과정으로 구축되었다.