• Journal of the Korean Society for Precision Engineering
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• v.12 no.2
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• pp.123-134
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• 1995

In this paper, the fast force algorithm has been studied so that it is used to calculate cutting forces and to develope the NC verification system. The NC verification using the fast force algorithm can verify excessive cutting force which is the cause of deflection and breakage of tool, and adjust the feed rate and spindle speed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.1
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• pp.85-91
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• 2003

The experimental study for turning circular free fanned surface with TiN coated insert tool was conducted for different cutting conditions such as cutting speed, feed rate and depth-of-cut. For the fluctuation of 1.0mm depth-of-cut, the characteristics for machined surface and tool wear were less influenced by the feed rate and cutting speed than those of higher depth of cut. The higher surface roughness and surface precision were obtained in lower cutting speed. For the fluctuation of 1.5mm depth-of-cut, the higher surface roughness was obtained for the case of the lower feed rate of 0.05-10mm/rev and the higher cutting speed of 80m/min. For the fluctuation of 2.0mm depth-of-cut, the surface roughness and surface precision were too worse to machine the specimen And the flank wear on the tool was increased rapidly rather than the crater wear.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.3
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• pp.20-25
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• 2003

The End-milling has been widely used in the industrial world because it is effective to cutting working with various shape. Recently the end-milling is demanded the high-precise technique with good surface roughness and rapid manufacturing time for precision machine and electronic elements. The cutting working of end-milling such as, cutting direction, revolution of spindle, feed rate and depth of cut have an effect on optimum surface roughness. This study was carried out to decide the working condition for optimum surface roughness and rapid manufacturing time by design of experiment and ANOVA. From the results of this study, the optimum working condition for end milling is upward cutting in cutting direction, 600rpm in revolution of spindle, 240mm/mm in feed rate, 2mm in axial depth of cut and 0 25mm in radial depth of cut. The design of experiment has become an useful method to select optimum working condition mend-milling.

• Journal of the Korean Society for Precision Engineering
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• v.2 no.3
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• pp.28-40
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• 1985

In this study, to check up on the effect of the components of cutting resistance upon friction between drill and inside wall of hole in drilling, the experiment was performed with individual specimen of carbon steel, cast iron, aluminium alloy under various cutting conditions: depth of hole, cutting speed, feed rate, shape and material of specimen. On the basis of the experimental results, the following conclusions are drawn; 1. The components of cutting resis- tance were increased in proportion to the increase of depth of hole owing to frictional resistance of drill margin and chip-jamming. 2. As feed rates increase, torque and thrust were increased. When comparing to the increasing rate for these components respecitively, thrust is higher tendency than torque. 3. As drill diameter increase, torque and thrust were increased. When comparing to the increasing rate for these components respectively, torque is higher tendency than thrust. 4. In the case of torque, the frictional resistance between drill margin and inside wall of drilled hole accounts for about 20 percent of carbon steel, 14 of cast iron, 10 aluminium alloy in drilling. But the effect of thrust force could be negligible. 5. Comparison between the theoretical and experimental results showed a close agreement so far as depth of hole is about three times of drill diameter. But there was a wide difference between them beyond the rane of three times, because of characteristics of the drilling process.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.6
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• pp.114-120
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• 2001

It is necessary to develop a new metal cutting technology which does not use cutting fluid, since cutting fluid can have undesirable effect on workers's health and working environment. For this to be possible, it is necessary to replace the conventional method of using cutting fluid, whose basic functions are removing chip and heat, and providing lubrication between tool and chip. In this work, cooled air is utilized in order to replace cutting fluid. Experiments were carried out while cutting workpiece with HSS flat endmill under a variety of supply conditions for cooled air. Also the performance characteristics of the air cooling system. which was built for the experiments, were carefully analyzed. For the reliable operation of air cooling system. moisture contained in the cooled air had to be removed before being supplied to the workpiece and tools. It was found that depending on the amount of its flow rate the temperature of cooled air changes at the time of injection from the nozzle. The flow rate of cooled air also plays an important role in removing the accumulated chip on the workpiece. After comparing the flank wear for the three cases of using cooled air, cutting fluid, and pure dry technique, it was demonstrated that the level of flank wear was similar for the cases of cooled air and cutting fluid. The pure dry technique, however, showed higher level of flank wear than cooled air.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.3
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• pp.99-103
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• 1998

The curved surface machined by plate end mill causes a excess non-cutting volume, in these cases ball end mill is used for the curved surfaces. This study is aimed to obtain the optimum cutting conditions of various cutting speed, table speed, tool diameter, radius of curvature roughness on the conditions of various cutting speed, tool diameter, radius of curvature when machining the curved surface using the ball end mill. After designing curve rates, obtaining NC data by CAD/CAM system through CC-Cartesian method and transferred the data through DNC system, we machined the specimens by the CNC machining center, The surface roughness of specimens was measured by surface roughness tester and CNC 3D coordinate measuring machine. The cutting condition were the same as follow velocity; 15, 20, 25 30m/min, feed rate;40, 60, 80, 100m/min and radius of curvature; 30,40,50,60mm, tool diameters; ø8, ø12, ø16, ø 20mm. Analizing the working results, we can acquire the optimum cutting condition of curved specimen at the cutting velocity of 20~25m/min and the feed rate of 80mm/min. As the same cutting condition the best surface roughness was showed at ø16mm of the tool diameter. But the tool diameter was smaller than ø8mm. we could improve for the surface roughness by controlling the cusp.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.4
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• pp.52-60
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• 1999

In this study the effect of roundness error with respect to the cutting conditions using the external cylindrical work piece by end mill cutting in a machining center was studied. the end mill used in this study is HSS coated with Ti-N which is of Ø 12-4 flutes. The material of workpiece is SM20C and cutting oil is used as a cooling flued The cutting experiments were carried out for the several cutting conditions(depth of cut height of end mill feed rate revolution per minute and cutting direction) and their roundness effects were compared using the least squares circle measuring method. The experimental results are summarized as follows : 1) The cutting depth is dominant for the roundness of a cylindrical work piece and the cutting speed must be determined precisely when the cutting depth is large 2) When the cutting direction in circular manufacturing is the same with the spindle rotation i.e up-cutting condition the surface roundness is also improved.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.1
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• pp.52-62
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• 2013

In order to obtain the relation between the cutting force and the process parameters in the chamfering process for the gear of a gear shaft, analysis of the process was performed with a simplified model instead of considering the whole actual 3-dimensional cutting situation produced between cutting tool and gear. The model divided the actual situation into the accumulation of hundreds of 2-dimensional layers with a small thickness in the direction of the height of gear and derived cutting force at a cutting position by accumulating each cutting force calculated in a layer. With proposed method to analyze the cutting forces in the chamfering process, it was revealed that the cutting position and size were exactly searched to calculate the cutting force in each layer. The total cutting force was the highest in the corner where the cutter encountered the gear first during the relative motion between them. The cutting forces were changed in proportion to the cutting parameters such as feed rate and trajectory.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.4 no.4
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• pp.21-27
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• 2005

Recently researches for high speed machining have been actively performed. Few analytical studies, however, have been published. In this paper, a model of cutting forces is analytically studied to predict cutting characteristics in end mill process, especially considering both feed rate and spindle speed. The developed cutting model is based on Oxley's machining theory, which predicts the cutting forces from input data of workpiece material properties, tool geometry and cutting conditions. Experimental verification has been performed to verify the predictive cutting force model using tool dynamometer. It has been found that the simulation results substantially agree with experimental results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.965-969
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• 1997

Due to the high feed rate,high speed machining (HSM) provide a great potential of rationalization for the machining Dies and Moulds. But determination of cutting condition is very difficult, because cutting mechanism of high speed machining is very complicated,especially using ball end-mill. This paoer gives a report on selection of the optimal cutting condition to improve the machining efficiency, And optimal machining condition is determined through the cutting force, FFT analysis of cutting force and surface roughness according to the cutting condition. Based on this experiment result,wear process and machining characteristics are evaluated.