• Journal of Computational Design and Engineering
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• v.3 no.2
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• pp.151-160
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• 2016

Cutter-workpiece engagement (CWE) is the instantaneous contact geometry between the cutter and the in-process workpiece during machining. It plays an important role in machining process simulation and directly affects the calculation of the predicted cutting forces and torques. The difficulty and challenge of CWE determination come from the complexity due to the changing geometry of in-process workpiece and the curved tool path of cutter movement, especially for multi-axis milling. This paper presents a new method to determine the CWE for general milling processes. To fulfill the requirement of generality, which means for any cutter type, any in-process workpiece shape, and any tool path even with self-intersections, all the associated geometries are to be modeled as triangle meshes. The involved triangle-to-triangle intersection calculations are carried out by an effective method in order to realize the multiple subtraction Boolean operations between the tool and the workpiece mesh models and to determine the CWE. The presented method has been validated by a series of case studies of increasing machining complexity to demonstrate its applicability to general milling processes.

• Textile Coloration and Finishing
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• v.34 no.3
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• pp.135-145
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• 2022

In this study, the dyeability of 0.06-denier-per-filament (dpf) ultrafine sea-island-type nylon knitted fabric was investigated and compared with that of 1.0-dpf general nylon with respect to four types of dyes. In particular, leveling, milling, half-milling, and metal-complex dyes were compared at concentrations of 0.5%, 1.0%, 2.0%, 4.0%, and 8.0% on-weight-fabric (o.w.f). In each case, staining was performed at 100 ℃. The dyeabilities of the materials were compared in terms of the depth of color as defined by the ratio of the absorption coefficient (K) to the scattering coefficient (S). Results indicated generally low K/S values for both the 0.06-dpf ultrafine sea-island-type nylon and 1.0-dpf general nylon. In terms of the dye type, the milling and half-milling dyes exhibited K/S values of ≥20 for all colors of yellow, red, and blue for the 0.06-dpf ultrafine yarn sea-island-type nylon, which were superior to those of the other dye types. Hence, the milling and half-milling dyes are considered more suitable than the other dyes. Further, a comparison of dye fastness and compatibility revealed that the half-milling dye was the most suitable dye for the 0.06-dpf ultrafine sea-island-type nylon.

• Journal of Biosystems Engineering
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• v.8 no.1
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• pp.17-29
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• 1983

The milling process is considered as causing one of the greatest grain losses among all the processes in rice post-production. Major source of grain losses in the rice milling is considered as the whitening process. This study was attempted to develop an abrasive-type whitener, the whitening chamber of which being supplied by jet-air evenly and continuously. To investigate the milling performance by the new whitener, three kind of emery-stone grit(#36, #41, and #46), and three levels of rotational speed of emery stone roller (950, 1070, and 1200 rpm) were tested. The jet-air abrasive-type whitener was also compared with the conventional abrasive-type having no jet-air blower in terms of their milling performance. In addition, the effect of different combinations of sequential uses of the abrasive- and friction-type whiteners on the milling performance was also experimentally evaluated. The results of this study are summarized as follows; 1. In general, the whitening system combined with the abrasive type whitener with jet-air supply, which was newly designed, and the existing jet-air friction type whiteners produces more milled- and head-rice by about 0.3% points and 2.8% points, respectively than the system combined with the existing abrasive type without the jet-air supply under the same operational conditions. The former also consumed less electricity by 0.024 KwH per 100kg of milled rice production and gave more milling capacity by about 35 kg/hr. As compared with the conventional whitening system consisting of jet-air friction type whiteners only, the former yielded more milled- and head-rice by 1.5% points and 4.4% points, respectively. 2. The abrasive roller having 46 grit emery was better than the roller having 36 grit in aspects of milling performance and machine efficiency, in general. 3. With regard to the effect of combination method of abrasive type and friction type whiteners, one pass in abrasive type plus three passes in friction type gave better milling performance and energy efficiency than the two passes in abrasive type plus two passes in friction type regardless of the designs of the emery stone rollers. 4. The increase in rotational speed of the emery stone roller from 950 rpm to 1200 rpm presented negative effects on milled and head-rice yields and machine efficiency, but slightly positive effect on milling capacity.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.895-898
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• 2001

This paper presents an optimization cutting speed(OCS) program developed to improve the machining precision and tool life in high speed machining using ball end milling. This program optimized the cutting speed that is changing at any time in free surface machining of an automobile part like a connecting load die. The technique of optimization cutting speed makes the CAD/CAM-generated NC code go through a reverse post process, conducts cutting simulation, and obtain the effective tool diameter of the ball end milling. Then it changes the spindle revolution to within the range of critical cutting speed fit for the material of the workpieces depending upon the effective tool diameter. In this study, the machining precision and tool life were compared for the two connecting load dies processed using the general cutting method and the proposed optimization cutting speed technique, respectively.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.4
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• pp.498-503
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• 2010

The main purpose of this study strongly concerned micro machining error estimation by using FEM analysis of tool deflection shapes in micro flat end-milling process. For the precision micro flat end-milling process, analysis of micro cutting errors is mandatory. In general, tool deflection is a major factor which causes cutting error and limits realization of the high-precision cutting process. Especially, in micro end-milling process, micro tool deflection generates very serious problems in contrast to macro tool deflection. Methods which deal with compensation of cutting error by tool deflection in macro end-milling process have been studied plentifully but, few researches transact with micro scaled cutting tool deflection in micro cutting process. Therefore, the trend of micro tool deflection was estimated by using FEM analysis in this paper. Cutting forces were acquired by micro dynamometer and these were utilized in FEM analysis. In order to verify FEM analysis results, micro machining processes were carried out and real machined profiles were compared with FEM results. Finally through the proposed approach well suited FEM results were obtained.

• Journal of Powder Materials
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• v.26 no.2
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• pp.101-106
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• 2019

Ni-based oxide dispersion strengthened (ODS) alloys have a higher usable temperature and better high-temperature mechanical properties than conventional superalloys. They are therefore being explored for applications in various fields such as those of aerospace and gas turbines. In general, ODS alloys are manufactured from alloy powders by mechanical alloying of element powders. However, our research team produces alloy powders in which the $Ni_5Y$ intermetallic phase is formed by an atomizing process. In this study, mechanical alloying was performed using a planetary mill to analyze the milling behavior of Ni-based oxide dispersions strengthened alloy powder in which the $Ni_5Y$ is the intermetallic phase. As the milling time increased, the $Ni_5Y$ intermetallic phase was refined. These results are confirmed by SEM and EPMA analysis on microstructure. In addition, it is confirmed that as the milling increased, the mechanical properties of Ni-based ODS alloy powder improve due to grain refinement by plastic deformation.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.86-89
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• 2002

In NC machining, the ability to automatically generate an optimal process plan is an essential step toward achieving automation, higher productivity, and better accuracy. For this ability, a system that is capable of simulating the actual machining process has to be designed. In this paper, a milling process simulation system for the general NC machining was presented. The system needs first to accurately compute the cutting configuration. ME Z-map(Moving Edge node Z-map) was developed to reduce the entry/exit angle calculation error in cutting force prediction. It was shorn to drastically improve the conventional Z-map model. Experimental results applied to the pocket machining show the accuracy of the milling process simulation system.

• Korean Journal of Computational Design and Engineering
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• v.7 no.1
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• pp.34-41
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• 2002

Five-axis NC machining, in general, is utilized in fabricating impellers, turbine blades, marine propellers that can be machined more effectively rather than three-axis machining. There have been many researches concerning tool interference avoidance, optimization of tool orientation. The C-space or Configuration-space was originated from the robotics area, which depicts interference-free joint-values in motion planning. In the paper we propose an optimizing scheme by which the maximum effective-radius of a face-milling cutter can be achieved for each CC(cutter-contact) point. Also the concept of a C-space for a CC point, the effective-radius map for 5-axis face-milling, and some illustrative examples of marine propeller machining, are presented.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.18 no.1
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• pp.110-115
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• 2009

In general, the radial error motion of a machine tool spindle system is effected on the accuracy of the parts to be made. This paper presents in milling process an investigation into spindle rotational accuracy effects on surface roughness of processing parts. We experimented the effects on spindle rotational accuracy in milling process by cutting AL 7075 workpiece at various rotational speed. In order to analyze the effects of rotational accuracy on surface roughness, we proposed the method using iSIGHT's RBF Approximation. The proposed method can be used fur anticipating the surface roughness when some spindle rotational accuracy experiments could be done in milling process.

• Journal of Biosystems Engineering
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• v.8 no.2
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• pp.62-68
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• 1983

This study was to examine the drying characteristics of barley and the effect of moisture content of barley on milling performance. A barley variety, Jogang, having 35.0% of initial moisture content was used for this experiment. Thermo-hydrostatic dryer which consists of blower, condensor, heater, humidifier, drying chamber and control box, etc., was used for the drying experiment. The change in the weight of a barley sample was continuously measured by means of the ring type load cell installed inside the drying chamber. Milling test runs the samples having the predetermined moisture content were taken from each drying test run. A laboratory type barley miller was used for the milling test. The results of the study are summarized as follows: 1. The drying constants (k) applied for the thin layer drying model, (M-Me)/(Mo-Me) = $Ae^{-kt}$ were 0.155, 0.259 and 0.548, respectively, at the three levels of drying temperatures, $40^{\circ}C$, $50^{\circ}C$ and $60^{\circ}C$. The drying constants complied with the Arrhenius Equation, K = Ko exp (-C/T), were determined as $Ko=1.901455{\times}10^8$ and C = 6563. 2. The laboratory milling test indicated that the highest milled and head barley recovery was resulted from the sample which was dryed at $40^{\circ}C$. In general, the increase in the drying temperature from $40^{\circ}C$ to $60^{\circ}C$ indicated a negative effect on milling yields. 3. Also, the sample having 15% M.C. presented the highest milled and head barley recovery among the five moisture content levels (12, 15, 18,21 and 24%).