• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.56-62
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• 2003

The precision fabrication of glass is increasingly demanded for the latest industrial applications of spherical lenses, micro-optical components, and so on. In many cases, the surface roughness of glass is required to be minute for improving the optical characteristics. In this paper, machining characteristics of SF-5 glass and quarts glass are studied by using the ELID grinding process to get mirror surface and productivity compared with a general lapping process. A rotary type grinder with air spindle was used for the experiments. Mitutoyo surface tester and AFM were also used to measure the grinded surface of glass. As the results of experiments, they showed that the surface roughness (Ra) of SF-5 glass was under 7.8 nm and that of quartz glass was under 3.0 m using the # 8000 grinder. So, the possibility of highly efficient and accurate surface for optical components can be achieved by the ELID grinding process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.04b
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• pp.108-113
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• 1993

The material for the machine tool structure should have high static stiffiness and damping in its property to improve both the static and dynamic performances. The static stiffness of a machine tool can be inceased by using either higher modulus material in the structure of a machine tool. However, the machine tool structrue with high stiffness but low damping is vulnerable to vibration at the resonance frequencies of the structure . For the high precision and highsped machine tool structure, therefore, the high damping capacity is most important in order to suppress vibration. The damping of a machine tool can not be increased by increasing the static stiffness. The best way to increase the damping capacity of the machine tool structure is to use a composite material which is composed of on material with high stiffness with low damping and another material with low stiffness with high damping. Therefore, in this paper, the bed of the ultra high precision grinding machine for mirror surface machining of brittle materials such as ceramics and composite materials was designed and manufactured with the epoxy concrete material. The epoxy concrete material was prepared by mixing epoxy resin with different size sands and gravels. The modulus, compressive strength, coefficient of thermal expansion, specific heat, and damping factor were measured by varying the compaction ratio, sizes and contents of the ingredients to assess the effect of the processing parameters on the mechanical properties of the material. Based of the measured properties, the prototype epoxy resin concrete bed for the mirror surface CNC grinding machine was designed and manufactured.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.1000-1004
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• 1995

In the case of the external cylindrical grinding machine, the grinding mechanism can cause a wheel to vibrate due to a wheel cutter. This phenomena will bring about the unsymmetric wear up to high frequency without any relation of rotational speed. So far, when the grinding spindle is analyzed, it is assumed that a wheel is considered as lumped mass at the endof a beam. Nowadays, there is a tendency to use the wheel with a lsrge diameter or CBN wheel to achieve the high speed and accuracy grinding performance. Therefore, this kind of assumption is no longer valid. At the analysis of the grinding spindle, the parameter which dapends on the dynamic characteristics is a combination force between each part. For example, there is the tightness torque of a bolt and taper element in the grindle. In addition, the material property of the wheel can contribute the dynamic characteristics. This paper shows the mode participation of the shell mode of the wheel in the grindle and the dynamic characteristics according to the parameters which are the configuration of the flange and tightness torque of a bolt and taper. Modal parameter of the wheel, flange and the spindle can be extracted through frequency response function obtained by modal test. After that, by changing the tightness torque and kinds of wheel, we could accomplish the test in the whole combined grinding spindle. To perform modal analysis of vibration characteristics in the grinding spindle, we could develop the model of finite element method.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.7
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• pp.70-77
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• 2003

The centerless through-feed grinding is performed by passing the workpiece between the grinding wheel and the regulating wheel. So, the amount of removed material around the leading end, of the workpiece is always more than that around the trailing end until the leading end leaves the grinding wheel. Because of this, there are differences in diameters along the workpiece axis during grinding, and workpiece axis is not parallel to the grinding wheel axis and the contact lines between the workpiece and wheels. Thus the ground workpiece shows tapering error inherently. To eliminate this error, the workpiece axis must be kept to be parallel to the grinding wheel axis. And, the direction of the workpiece axis can be controlled by the work-rest blade. Therefore, the effects of work-rest blade inclination angle on the through-feed centerless ground part are investigated in this study. As a result, it is found that there is a positive inclination angle of the work-rest blade for minimizing the tapering error of a ground workpiece.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.918-921
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• 2001

In grinding process, the heat of $1200^{\circ}$~$1500^{\circ}$ on the grinding area between grinding wheel and workpiece is generated. It decreases the surface integrity of workpiece and causes the thermal damages such as the deformed layer, residual stress and grinding burn. Generally coolant is widely used for preventing the heat generation on the grinding area, but it deteriorates the working condition by polluting the atmosphere of workplace and in the end pollutes the environment. The grinding methods using the compressed cold air and mist are the cooling methods to substitute conventional coolant. They can decrease the environmental pollution through not using coolant any more or minimizing it. In this study, the cooling effects of grinding methods using the compressed cold air and mist have been investigated. The grinding system equipped with the water bathe and mist spray nozzle was developed. The energy partition to workpiece through measuring the temperature on the workpiece surface was calculated. The surface integrity of workpiece and thermal damage like the deformed layer were analyzed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.875-879
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• 2000

In the previous report1), the grinding characteristics of quartz were investigated. In this paper, the grinding mechanisms of brittle materials including ceramics and quartz are modeled and a new parameter SDR(Surface roughness Direction Ratio) is proposed to characterize the grinding mechanisms of such materials. A set of experiments were performed to verify the effectiveness of the suggested parameter. The experimental results indicate that the plastic deformation is the dominant material removal mode at the grinding conditions which show the higher value of SDR. In the case of quartz, the material was removed by brittle fracture in a lower value of SDR and by plastic deformation in a higher value of it. SDR is not affected by wheel mesh size when brittle fracture occured. But in the plastic deformation case, SDR value increases with wheel mesh size.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.997-1001
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• 2000

In this paper, the case studies of reducing rotational errors is theoretically done for a grinding spindle with an active magnetic bearing system. The rotational errors acting on the magnetic bearing spindle are due to mass unbalance of rotor, runout, grinding excitation and unmodeled nonlinear dynamics of electromagnets. For the most case, the electrical runout of sensor target is big even in well finished surface, this runout can cause a rotation error amplified by feedback control system. The adaptiveed forward method based on LMS algorithm is discussed to compensate this kind of runout effects, and investigated its effectiveness by numerical simulation and experimental analysis. The electrical runout form the rear sensor target of grind spindle is about 70$\mu\textrm{m}$ with harmonic frequencies. The rotor orbit size in rear bearing is reduced about to 5$\mu\textrm{m}$ due to 1X and 2X rejection by feedforward control.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.999-1002
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• 1997

In this study, in order to set ELID conditions in the internal grinding wheel, the characteristics with the variations of grit size, output voltage and peak current were examined by using conventional machining center(M/C) equipped with electrolytic in-process dressing(EL1D). The initial working voltage was lowered and the working current was high with increasing grit size. The insulating layer thickness increased, as the final voltage increased with the output voltage and peak current. The initial wear rate of the wheel machined with ELID were measured indirectly by using surface roughness tracer. The initial wear rate of the wheel with ELID increased along with high grit size. In case that the grit size with ELID was low, the output voltage and peak current had to be increased to increase the insulating layer thickness. In case of the high grit size, the output voltage and the peak current were established low, which made the insulating layer thickness decreased.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.94-97
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• 2003

A precise fabrication technology of glass is increasingly demanded fer the latest Industrial applications of spherical lenses. micro-optical components, laser applications and so on. Most of cases, the surface roughness of glass is required to be minute for improving the optical characteristics. Then. the machining characteristics of SF-5 glass and quarts glass were studied by using the ELID grinding process to get mirror surface and productivity compared with a general lapping process. A rotary type grinder with ELID generator was used to make the mirror surface of glass and a Mitutoyo surface tester and a nano-hardness tester were also used to measure the grinded surface or glass. As the results of experiments. they showed that the surface roughness(Ra) of SF-5 glass was under 7.8 nm and that of quartz glass was under 3.0 nm using the # 8000 grinder. So, the possibility of highly efficient and accurate surface for optical components can be achieved by the ELID grinding process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1992.10a
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• pp.136-144
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• 1992

Recently, Silicon Nitrde ceramic is regarded as the representative engineering ceramic with the excellent mechanical properties and many functions for mechanical components and parts among various kinds of ceramics in the mechanical industry. But, during the manufacturing of engineering ceramics, there is many volumetric shrinkage coupled with a distortion of the parts which is produced. Due to the requirement for high accuracy of size, form, and surface finish of the components, machining is needed surely. Nowdays, grinding with a resin bond type diamond wheels has been generally applied to machining of the engineering ceramics in the whole world because that it can be conveniently proceeded for workers to dress of tool and made with high reliability in producing factories among many bond type super-abrasive wheels yet. It is important task for attaining prescribed mechanical components with high reliability to observe the grinding mechanism of ceramics as like generation of cracks and chipping of material during process. Because they considerably effects on the strength characteristic of machined mechanical components. In this study, various surface grinding experiments using resin bond type diamond wheels are carried out for Silicon Nitride ceramic. Grinding mechanism of ceramics is observed experimentally and the relationship with various conditions is also attained. Form this experimental study, some useful machining data and information to determine proper machining condition for grinding of Silicon Nitride ceramic is obtained.