• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 1994년도 추계학술대회 논문집
• /
• pp.49-54
• /
• 1994

A dynamic model for the cutting process in the end milling process is developed. This model, which describes the dynamic response of the end mill, the chip load geometry including tool runout, the dependence of the cutting forces on the chip load, is used to predict the dynamic cutting force during the end milling process. In order to predict accurately cutting forces and tool vibration, the model, which uses instantaneous specific cutting force, includes both regenerative effect and penetration effect. The model is verified through comparisons of model predicted cutting force with measured cutting forces obtained from machining experiments.

• 한국기계가공학회지
• /
• 제13권2호
• /
• pp.108-116
• /
• 2014

Considering the run-out effect and cutting force coefficients, the cutting force profile of half immersion end-milling was analyzed in detail. The effects of three specific cutting-force coefficients and three edge-force coefficients are verified. Through a detailed investigation, it is proved that the radial cutting force coefficients and are the major factors which increase the cutting forces Fx and Fy in end-milling. However, the axial cutting force coefficients have no influence on the force Fx and Fy changes in end-milling. Also, the analyzed end-milling force model shows good consistency with the actual measured force with regard to Fx and Fy. Thus, this model can be used for the prediction of the force history in end-milling with run-out, and it incurs a different force history with different start and exit immersion angles as well as holding effects.

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

• 한국정밀공학회지
• /
• 제16권6호
• /
• pp.83-89
• /
• 1999

This paper presents the in-process runout compensation methodology to improve the surface quality of circular contouring cut in end milling process. The runout compensation system is based on the manipulation of workpiece position relative to cutter in minimizing the cutting force oscillation at spindle frequency. the basic concept of this approach is realized on a end milling machine whose machining table accommodates a set of orthogonal translators perpendicular to the spindle axis. The system performed that measuring the runout related cutting force component, formulating PI controlling commands, and the manipulating the workpiece position to counteract the variation of chip load during the circular contouring cut. To evaluate the runout compensation system performance, experimental study based on the implementation of two-axes PI force control is presented in the context of cutting force regulation and part surface finish improvement.

• 한국생산제조학회지
• /
• 제5권2호
• /
• pp.63-72
• /
• 1996

In order to regulate the cutting force at a desired level during peripheral end milling processes a feedrate override Adaptive Control Constraint (ACC) system was developed. The feedrate override function was accomplished through a development of programmable machine controller (PMC) interface technique on the NC controller, Nonlinear model of the cutting process was linearized as an adaptive model with a time varying process parameter. An integral type estimator was introduced for on-line estimation of the cutting process parameter, Zero order hold digital control methodology which uses pole-assignment concept for tuning of PI controllers was applied for the ACC system. Performance of the ACC system wsa confirmed on the vertical machining center equipped with fanuc OMC through a large amount of experiment.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 2003년도 춘계학술대회 논문집
• /
• pp.167-172
• /
• 2003

The machining method by using end-milling tool has been applying in machining structures of various shapes because of the availability. Recently, all kinds of industries based on the parts of micro shape are developing, and the demands of mechanical micro machining technology are Increasing suddenly to produce these parts. According to such changes, the technology of the micro end-milling machining is applying as one of the most important machining means. This research is to aim at developing machining technology for various micro structures using micro end-mill. This paper introduces micro mechanical machining system with ultra precision, and demonstrates methods manufacturing all sorts of parts and moldings for industry and examples of applicable machining by using micro end-milling tool of micro sizes from hundreds to tens in diameter.

• 한국공작기계학회:학술대회논문집
• /
• 한국공작기계학회 2000년도 춘계학술대회논문집 - 한국공작기계학회
• /
• pp.3-7
• /
• 2000

In this study, a modified model for prediction of cutting force components in up end milling process is presented. Using this cutting force components of 4-tooth endmils with various helix angles have been predicted. Predicted value of cutting force components are well coincide with the measured ones. As helix angle increases overlapping effects of the active cutting edges increase and as a result the amplitudes of cutting force components decrease and the specific cutting energy consumed also decreases

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2000년도 춘계학술대회 논문집
• /
• pp.912-916
• /
• 2000

The term ‘High Speed Machining’has been used for many years to describe end milling with small diameter tools at high rotational speeds, typically 10,000 - 100,000 rpm. The process was applied in the aerospace industry fur the machining of light alloys, notably aluminium. In recent you, however, the mold and die industry has begun to use the technology for the production of components, including those manufactured from hardened tool steels. And the end mill is an important tool in the milling process. A typical examples for the end mill is the milling of pocket and slot in which a lot of material is removed from the workpiece. Therefore the proper selection of cutting parameter fur end milling is one of the important factors affecting the cutting cost. The one of the advantages of HSM is cutting thin-walled part of light alloy like Al(thinkness about 0.1mm). In this paper, firstly, we study characteristics of HSM, and then, we choose the optimal parameters(cutting forces) to cut thin-walled Al part by experiment.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 1997년도 추계학술대회 논문집
• /
• pp.985-988
• /
• 1997

In end milling process, the undeformed chip section area and cutting forces vary periodically with phase change of the tool. However the real undeformed chip section area deviates from the geometrically ideal one owing to cutter runout and tool shape error. In this study ,a method of estimating the real undeformed chip section area which reflects cutter runout and tool shape error was presented in up end milling process using measured cutting forces. Size effect was identified from the analysis of specific cutting resistance obtained by using the modified undeformed chip section area.

• Advances in materials Research
• /
• 제7권2호
• /
• pp.137-148
• /
• 2018

The present paper is a contribution in characterising end milling process of AISI 52100 ball bearing steel through statistical analyses of variance (ANOVA). The latter has been performed to identify the effect of the cutting parameters on the machined surface roughness and the cutting tool life. Wear measurements have been carried on multilayer coated carbide inserts and the respective surface roughness has been recorded. Taguchi's technique has been adapted to conduct the design experiments in terms of orthogonal arrays according to the cutting parameters (cutting speed, feed rate and depth of cut), the type of coating (TiN, TiCN, TiAlN) and lubricating condition. Regression analyses have conducted to the development of simplified empirical models that can be effectively used to predict surface roughness and tool wear in the present milling process.