• Journal of the Korean Society for Precision Engineering
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• v.11 no.5
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• pp.153-160
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• 1994

In this study, residual stress and surface roughness were investigated experimentally to evaluate surface integrity on surface layer machined by CBN, ceramics and WC cutting tools. When machining difficult-to-cut material (hardened STD11 steel $H_{R}$C 60), residual stresses remaining in machined surface layer were mainly compressive. The increase of flank wear caused a shift of the compressive residual stress maximum to greater workpiece depths, but the changes did not penetrate the workpiece beneath a depth of 300 .mu. m. Surface roughness was influenced considerably by variations of the cutting speed and feed. In machining hard material, CBN and A1$_{2}$ $O_{3}$ ceramics cutting tool materials proved significantly superior to mixed ceramics A1$_{2}$ $O_{3}$-TiC and WC in evaluation of surface integrity.y.

• Journal of the Korean Society of Safety
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• v.24 no.2
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• pp.7-12
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• 2009

The machining process of ceramics can be characterized by cracking and brittle fracture. In the machining of ceramics, edge chipping and crack propagation are the principal reasons to cause surface integrity deterioration. Such phenomenon can cause not only poor dimensional and geometric accuracy, but also possible failure of the ceramic parts. Thus, traditional ceramics are very difficult-to-cut materials. Generally, ceramics are machined using conventional method such as grinding and polishing. However these processes are generally costly and have low MRR(material removal rate). To overcome such problems, in this paper, h-BN powder, which gives good cutting property, is added for the fabrication of machinable ceramics by volume of 10 and 15%. The purpose of this study is an analysis of endmill's rake angle for appropriate tools design and manufacturing for the machinable ceramics. In this study, Experimental works are executed to measure cutting force, surface roughness, tool fracture, on different axial rake angle of endmills. Cutting parameters, namely, feed, cutting speed and depth of cut are used to accomplish purpose of this paper. Required experiments are performed, and the results are investigated.

• Journal of the Korean Society of Safety
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• v.24 no.1
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• pp.1-6
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• 2009

In machining of ceramic materials, they are very difficult-to cut materials because of there high strength and hardness. Machining of ceramics are characterized by cracking and brittle fracture. Generally, ceramics are machined using conventional method such as grinding and polishing. However these processes are generally costly and have low MRR(material removal rate). This paper focuses on machinability evaluation of machinable ceramics for products with CNC machining center. Thus, in this paper, experiment applying cutting parameters is performed based on experimental design method. A design and analysis of experiments is conducted to study the effects of these parameters on the surface roughness by using the S/N ratio, analysis of ANOVA, and F-test. And multiple linear regression analysis is applied to compare experimental with predicted data in consideration of surface roughness. Cutting parameters, namely, feed, cutting speed and depth of cut are used to accomplish purpose of this paper. Required experiments are performed, and the results are investigated.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.52-57
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• 2000

STD11 is one of difficult-to-cut materials and its cutting characteristic data is not built enough. A bad cutting condition of it leads to low productivity of die and mould, so it is necessary to evaluate the machining characteristics of STD11. In this paper, the relations of the geometry of ball-end mill and mechanics of machining with it are studied. The helix angle of ball-end mill varies according to a location of elemental cutting edge in the cutting process are difficult to calculate accurately. To calculate instantaneous cutting forces, it is supposed that the tangential, radial and axial cutting force coefficients are functions of elemental cutting edge location. Elemental cutting forces in the x,y and z direction are calculated by coordinate transformation. The total cutting forces are calculated by integrating the elemental cutting forces of engaged cutting edge elements. This model is verified by slot and side cutting experiments of STD11 workpiece which was heat-treated to HRC45.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.1033-1037
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• 1997

In the end milling process, the information of axial and depths of cut plays an important role in adaptive control systems for precision machining and tool monitoring systems for unmanned machining. In general, it is not easy to know the depths of cut due to irregular shape of workpieces, inaccurate positioning of them on the table of machine tool and machining error in previous cutting. In addition to, even they are informed, it is difficult to match the individual position of the cutter on the varying shape of the work material. This work suggest an algorithm estimating the depths of cut based on cutting force sigal. The proposed algorithm can be applied in more extensive cutting situations, for example, presence of the tool wear, variation of work material hardness, etc.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.4 s.175
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• pp.900-906
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• 2000

Ceramic, PCD and CBN tools are available for the difficult-to-cut-materials such as hardened carbon tool steel, stainless steel, Inconel 718 and etc. Ceramic tools are likely to be chipped and abruptly broken before the appearance of normal wear in turning. Ceramic tools are suitable for continuous in turning, not for intermittent in milling. In this study, TiN/TiCN multi-layer coated ceramic tools were found to restrain the chipping, breaking and early fracture and to increase the critical cutting speed owing to TiN/TiCN multi-layer coating in Arc Ion Plating of PVD method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.2
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• pp.3-9
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• 2004

The main objectives of this paper are to determine optimum cutting conditions using experimental design method to manufacture pedicle screws. Generally, titanium alloys are known as difficult-to cut materials. In the machining of titanium alloy, high cutting temperature and strong chemical affinity between the tool and the work material are generated because of Its low thermal conductivity and chemical reactivity. Such phenomenon cause increase of tool wear and deterioration of surface quality. Thus, in this paper, required experimental investigations are performed to evaluate the machinability of titanium materials With tungsten carbide tools Required simulation and experiments are performed, and the results are investigated.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.365-369
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• 2004

The Advantages of hot machining are the reduction of cutting forces, tool wear, and the increase of material removal rates. In this study, a hot-machining using gas flame heating characteristics of milling by CBN tip was analyzed, and the influence of the surface temperature and the depth of cut on the tool life were investigated. The results show that hot machining of tungsten carbide-alloyed is more effective than conventional machining. In addition, some advantages obtained from hot machining, such as decrease of tool wear and cutting force, high surface quality.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.8
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• pp.53-62
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• 1995

In recent years, the rapid development of the machine tool and tough insert has made metal removal rates increase, and automatic system without human supervision requires a higher degree reliability of machining process. Therefore the control of chips is one of the important topics which deserves much attention. The chip classification was made based upon standard deviation of the mean cutting force measured by a tool dynamometer. STS304was chosen as the workpiece which is known as the difficult-to-cut material and mainly saw-toothed chip produced, and the chip type according to the standard deviation of mean cutting force was classified into five categories in this experiment. Long continuous type chip which interrupts the normal cutting process, and damages the operator, tool and workpiece has low standard deviation value, while short broken type chip, which is favourable chip for disposal, has relatively large standard deviation value. In addition, we investigated the possibility that the chip type can be predicted analyzing the relationship between chip type and cutting condition by the trained neural network, and obtained favourable results by which the chip type can be predicted with cutting conditon before cutting process.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.297-301
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• 2002

High-speed machining generates concenter thermal/frictional damage at the cutting ed rapidly decreases the tool life. This paper I at determining the effect of cutter orienter the cutting environment on tool life, tool mechanism when down milling. In this paper, experiments were carried out in various tool and cutting environments, such as dry, wet compressed chilled air, tool life were measu evaluate machinability in high-speed milli difficult-to-cut material and die steel, Tool measured in horizontal upwards, horiz downwards, vertical upwards and vert downwards. In addition, tool life was measur dry, wet and compressed chilled air. For this a compressed chi1led-air system was manufact The results show that a horizontal cutter ori provided a longer tool life than a vertical orientation. With respect to the cutting envi compressed chilled air increased tool life. H the wet condition decreased tool life due thermal shock caused by excessive cooling high-speed mill ins and the compressed chilled had little effect.