• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1789-1794
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• 2003

As a new approach to analyze shear behaviors in the shear plane and chip-tool friction behaviors in the chip-tool contact region during an end milling process, this paper introduces a method to transform an end milling process to an equivalent oblique cutting process. In this approach, varying undeformed chip thicknesses and cutting forces in the up-and down-end milling process are replaced with the equivalent ones of oblique cutting. Accordingly, in the current paper, the shear and friction characteristics of end milling operations, up- and down-end milling, have been analyzed based on the equivalent oblique cutting models. Two series of cutting tests, up- and down-end milling tests and the equivalent oblique cutting tests to that, have been carried out to verify the validity of the analyses. And using the results of cutting tests the cutting characteristics of the up- and down-end milling processes have been thoroughly investigated.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.4
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• pp.19-24
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• 2003

In end milling process, which is characterized by the use of a rotating tool, the undeformed chip thickness varies periodically with phase change of the tool. Although many efforts have concentrated on the study of end milling process, the analysis of shear and chip-tool friction behaviors has not been reported. Recently, a model has been proposed to simulate the shear and friction characteristics of an up-end milling process in terms of the equivalent oblique cutting. In the current study, the varying undeformed chip thickness and the cutting forces in a down-end milling process are replaced with the equivalent ones of oblique cutting. Then it is possible to simulate the shear and the chip-tool friction characteristics of a down-end milling process. The proposed model has been verified through two sets of cutting tests i.e., down-end milling and the equivalent oblique cutting tests. The experimental results show that the proposed model is suitable to analyze the shear and chip-tool frictional characteristics of down-end milling process. The specific cutting energy decreases with increase in equivalent undeformed chip thickness in a down-end milling process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.902-906
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• 2000

In end milling process the undeformed chip thickness and the cutting force components vary periodically with phase change of the tool. In this study, up end milling process is transformed to the equivalent oblique cutting. The varying undeformed chip thickness and the cutting force components in end milling process are replaced with the equivalent average ones. Then it can be possible to analyze the chip-tool friction and shear process in the shear plane of the end milling process by the equivalent oblique cutting model. According to this analysis, when cutting SM45C steel. 82% of the total energy is consumed in the shear process and the balance is consumed in the friction process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.887-890
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• 2001

In end milling process the underformed chip thickness and the cutting force components very periodically with phase change of the tool. In this study, up end milling process is transformed to the equivalent oblique cutting. The varying underformed chip thickness and the cutting force components in end milling process are replaced with the equivalent average ones. Then it can be possible to analyze the chip-tool friction and shear process in the shear plane of the end milling process by the equivalent oblique cutting mode. According to this analysis, when cutting Inconel 718.61% of the total energy is consumed in the shear process and the balance is consumed in the friction process.

• Proceedings of the KSME Conference
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• 2000.11a
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• pp.724-729
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• 2000

In end milling process the undeformed chip thickness and the cutting force components vary periodically with phase change of the tool. In this study, up end milling process is transformed to the equivalent oblique cutting. The varying undeformed chip thickness and the cutting force components in end milling process are replaced with the equivalent average ones. Then it can be possible to analyze the chip-tool friction and shear process in the shear plane of the end milling process by the equivalent oblique cutting model. According to this analysis, when cutting SM45C steel, 72% of the total energy is consumed in the shear process and the balance is consumed in the friction process.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.10
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• pp.1520-1527
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• 2001

In end milling process the undeformed chip thickness and the cutting force components vary periodically with phase change of the tool. In this study, up end milling process is transformed to the equivalent oblique cutting. The varying undeformed chip thickness and the cutting force components in end milling process are replaced with the equivalent average ones. Then it can be possible to analyze the chip-tool friction and shear process in the shear plane of the end milling process by the equivalent oblique cutting model. According to this analysis, when cutting SM45C steel, 72% of the total energy is consumed in the shear process and the balance is consumed in the friction process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.4
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• pp.7-12
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• 2012

The cutting force for peripheral end-milling considering run-out property was estimated and its result was compared with that of measured one. An experimental coefficient modelling was used for the formulation of theoretical end-milling force by considering the specific cutting force coefficient. Also, the specific cutting force, that is the multiplication of specific cutting force coefficient and uncut chip thickness, was used for the prediction of end-milling force. The end-milling force mechanics with run-out was presented for the estimation of theoretical force in peripheral end-milling by considering the geometric shape of the workpiece part. As a result, the estimated end-milling force shows a good consistency with the measured one. And it can be used for the prediction of force history in end-milling with run-out which incurs different start and exit immersion angle in entering and exiting condition.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.77-82
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• 2003

In end milling process, undeformed chip thickness and cutting force vary periodically with phase change of the tool. Recently, a model has been proposed to simulate the shear and friction characteristics of an up-end milling process in terms of the equivalent oblique cutting to this. In the current study, the varying undeformed chip thickness and the cutting forces in a down-end milling process have been replaced with the equivalent ones of oblique cutting. And, the down-end milling characteristics of SM45C has been compared with that of the up-end milling previously presented with different helix angles.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.223-228
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• 2003

In end milling processes, characterized by use of rotating tools, the underformed chip thickness varies periodically with the phase change of tool. In current study, as a new approach to analyse shear behaviors In the shear plane and chip-tool friction behavior chip-tool contact region during an end milling process. In this approach, an up-end milling process is transformed into an equivalent oblique cutting process. Experimental investigations for two sets of cutting tests i.e.. up-end milling and the equivalent oblique cutting test were performed to verify the presented model.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.4
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• pp.13-19
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• 2012

There are many dynamic properties in measured end-milling force. So, it is difficult to predict the real static property of end-milling force. Also the behavior of end-milling force is very complex to predict with the measured one. To extract the static property from measured force, it must be filtered and its problem is closely related to a de-noising one. Also this paper presents alternative de-noising method of end-milling force using wavelet filter bank, based on the wavelet transform and its inverse one. In this paper, by comparing the measured force and its wavelet filtered one, the fundamental end-milling force property after wavelet transform is well reviewed and analyzed. This result of wavelet filtering with filter bank shows the static force of end-milling which has severe dynamic properties occurring in entry and exit state of edge emersion into the workpiece.