• 한국생산제조학회지
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• 제18권3호
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• pp.261-269
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• 2009

Micro end-milling process is applied to fabricate precision mechanical parts cost-effectively. It is a complex and time-consuming job to select optimal process conditions with high productivity and quality. To improve the productivity and quality of precision mechanical parts, micro end-mill wear and cutting force characteristics should be studied carefully. In this paper, high speed machining experiments are studied to construct the optimum process design as well as the mathematical modeling of tool wear and cutting force related to cutting parameters in micro ball end-milling processes. Cutting force and wear characteristics under various cutting conditions are investigated through the condition monitoring system and the design of experiment. In order to construct the cutting database, mathematical models for the flank wear and cutting force gradient are derived from the response surface method. Optimal milling conditions are extracted from the developed experimental models.

• 한국기계가공학회지
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• 제18권10호
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• pp.27-33
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• 2019

The aviation industry has grown beyond the simple processing and assembling of aircraft parts and now designs and exports finished aircraft. In this study, the vertical CNC milling rotational speed and feed rate were parameters to investigate the life of tools according to their shape: (flat, round, and ball end mill) in the rough cutting of titanium. These tools are widely used in aircraft manufacturing and assembly. The purpose of this study is to measure the cutting temperature generated during the cutting process and calculate the rate of tool wear. This will be accomplished by measuring the tool weight before and after cutting the specimen and to compare it with the results of previous studies. Our study showed that the maximum cutting temperature increased as cutting time, tool rotational speed, and feed rate increased. The highest cutting temperatures were recorded for the ball, round, and flat end mill, respectively. Tool wear for the ball, round, and flat end mill increased as the speed and feed rate increased. The flat end mill exhibited the highest rate of wear from a minimum of 0.62% to a maximum of 2.88%.

• Journal of Mechanical Science and Technology
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• 제18권5호
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• pp.770-779
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• 2004

This paper describes the micro cutting of wear resistant tungsten carbides using PCD (Poly-Crystalline Diamond) cutting tools in performance with SEM (Scanning Electron Microscope) direct observation method. Turning experiments were also carried out on this alloy (V50) using a PCD cutting tool. One of the purposes of this study is to describe clearly the cutting mechanism of tungsten carbides and the behavior of WC particles in the deformation zone in orthogonal micro cutting. Other purposes are to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, machined surface and tool wear rates by the outer turning of this alloy carried out using the PCD cutting tool during these various cutting conditions. A summary of the results are as follows: (1) From the SEM direct observation in cutting the tungsten carbide, WC particles are broken and come into contact with the tool edge directly. This causes tool wear in which portions scrape the tool in a strong manner. (2) There are two chip formation types. One is where the shear angle is comparatively small and the crack of the shear plane becomes wide. The other is a type where the shear angle is above 45 degrees and the crack of the shear plane does not widen. These differences are caused by the stress condition which gives rise to the friction at the shear plane. (3) The thrust cutting forces tend to increase more rapidly than the principal forces, as the depth of cut and the cutting speed are increased preferably in the orthogonal micro cutting. (4) The tool wear on the flank face was larger than that on the rake face in the orthogonal micro cutting. (5) Three components of cutting force in the conventional turning experiments were different in balance from ordinary cutting such as the cutting of steel or cast iron. Those expressed a large value of thrust force, principal force, and feed force. (6) From the viewpoint of high efficient cutting found within this research, a proper cutting speed was 15 m/min and a proper feed rate was 0.1 mm/rev. In this case, it was found that the tool life of a PCD tool was limited to a distance of approximately 230 m. (7) When the depth of cut was 0.1 mm, there was no influence of the feed rate on the feed force. The feed force tended to decrease, as the cutting distance was long, because the tool was worn and the tool edge retreated. (8) The main tool wear of a PCD tool in this research was due to the flank wear within the maximum value of $V_{max}$ being about 260 $\mu\textrm{m}$.

• 동력기계공학회지
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• 제20권5호
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• pp.5-13
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• 2016

This study is on wear damage of the material for a molding machine that be used at finally cutting of metal beam made in roll forming process of vehicle bump beam process line. SKD11 steel was used with the material for cutting mold jig. In the cutting mold jig, Ti diffusion heat treatment after vacuum heat treatment was carried out for upgrade of surface hardness and anti-wear. Also, the heat treatments by various methods were performed to compare the wear damage degree against above the existing heat treatment. Wear loss and friction coefficient were obtained from wear test. And, micro Vickers hardness values were compared with damaged parts or not of cutting mold jig. Micro Vickers hardness value appeared higher at the undamaged part by Ti diffusion heat treatment. The micro Vickers hardness well followed a two-parameter Weibull probability distribution.

• 대한기계학회논문집A
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• 제28권2호
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• pp.196-205
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• 2004

The cutting characteristics and the deformed layer of nitrogen(N)-added type 316LN stainless steel were comparatively investigated to type 316L stainless steel. The cutting force, the surface roughness(Ra) and the tool wear in face milling works were measured with cutting conditions, and the deformed layers were obtained from micro-hardness testing method. The cutting resistance of type 316LN was similar to type 316L in spite of its high strength. The surface roughness of type 316LN was superior to type 316L for all the cutting conditions. In particular, in the high cutting speed above 345m/min, the surface roughness of the two stainless steels was closely same. The deformed layer thickness of the two stainless steels was generated in the 150$\mu\textrm{m}$-300$\mu\textrm{m}$ ranges, and its value of type 316LN was lower than that of type 316L. This is due to the high strength properties by nitrogen effect. It was found that type 316LN was higher in the tool wear than that type 316L, and flank wear was dominant to crater wear. In face milling works of type 316LN steel, tool wear is regarded as a important problem.

• 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 1993년도 추계학술대회 논문집
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• pp.58-63
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• 1993

The charactistics of AE(Acoustic Emission) signal is related to cutting conditions, tool materials and tool geometry in metal cutting. The tool geometry change which is derived from tool wear affects the source of AE signal in machining process. The relationship between AE signal and tool wear was experimentally investigated. THe value of RMS(Root Mean Sequare) and Amplitude of AE signal were increased in tool wear condition. Also the high value of Count per Hit and Count vs. Frequency was observed in this condtion. As a result, tool wear can be effectively detected by AE signal during cutting operation.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 춘계학술대회 논문집
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• pp.135-139
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• 1996

In this a paper, a new method to measure the wear of the single crystal diamond(SCD) tool using image processing is presented. To increase resoultion, high magnifying lens is used and to enlarge the measurement field of view, a image region matching method is applied. The shape of SCD tool is modeled by mathematical analysis. Cutting edge chipping and wear are calculated by the model. This method is proved to be efficient in detecting a few micron of wear and cutting edge loss by chipping along the whole cutting edge.

• 한국정밀공학회지
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• 제8권3호
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• pp.44-54
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• 1991

A Study was made on falnk wear in carbide tools in turning SUS304 steel. When an austenitic stainless steel (SUS304 steel) is cut with the tool, saw-toothed chip are produced. It is found that machining SUS304 steel would make a tool worn fast. For increasing productivity, tool wear has to be predicted and controlled. An amended cutting geometry consisting of a negative rake angle ($-6^{\circ}$ ) and a high clearance angle ($-17^{\circ}$ ) is proposed for decreasing carbide tool wear (flank) in the machining of SUS304 steel. The amended cutting geometry is found to make the flank wear lower than a general cutting geometry (rake angle $6^{\circ}$ , clearance angle $5^{\circ}$). The effects of the three cutting variables (cutting speed, feed, tool radius) on the flank wear analyzed by fiting a simple first-order model containing interaction terms to each flank wear parameter by means of regression analysis and the predicted from first-order regression analysis model equation of flank wear.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 추계학술대회 논문집
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• pp.20-25
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• 1996

The needs to machine hardened steels with high productivity and good surface integrity have been increased in the dies ＆ molds industry. This paper presents some experimental results on the CBN ball endmilling for hardened tool steel. This investigation concerns on the effects of cutting speed and cutting fluids on the cutting performance such as cutting forces, tool wear, and surface finish. The wear of CBN ball endmill for each cutting conditions were also examined through the microscopic observation. It has been found out that the higher cutting speeds with cutting fluids result in better cutting performance.