• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2004.11a
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• pp.1056-1061
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• 2004

The vibration of rotor systems is caused by various factors, such as misalignment, unbalance, gear meshing, error of assembly, etc. Modal test and TDA/ODS analysis were done. The dynamic analysis of the armature was done with SAMCEF which is a commercial software for finite element and kinematic analysis. The transient response of the armature is calculated by the SAMCEF with the consideration of magnetic force and bearing stiffness, which are the essential elements for the design of high speed cutter. Main frequency of the vibration is due to the unbalance of the armature. The FEM analysis model considering unbalance and the high speed cutter have same vibration properties. The vibration sources of the high speed cutter is proved to be unbalance.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.12
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• pp.21-28
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• 2004

In modem manufacturing industries such as the airplane and automobile, aluminum alloys which are remarkable in durability have been utilized effectively. High-speed machining technology for surface roughness quality of workpiece has been applied in these fields. Higher cutting speed and feedrates lead to a reduction of machining time and increase of surface quality. Furthermore, the reduction of time required for polishing or lapping of machined surfaces improves the production rate. Traditional milling process for high speed cutting can be machined with end mill tool. However, such processes are generally cost-expensive and have low material removal rate. Thus, in this paper, face milling cutter which gives high MRR has developed face milling cutter body for the high speed machining of light alloy to overcome the problems. Also vibration experiment to detect natural frequency in free state and frequency characteristics during machining are performed to escape resonance.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.155-160
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• 2002

Recently, the development of aerospace and automobile industries has brought new technological challenges, rebated to the growing complexity of products and the new geometry of the models. High speed milling with a 5-Axis milling machine has been widely used fur 3D sculptured surface parts. When turbine blades are machined by a 5-axis milling, their thin and cantilever shape causes vibrations, deflections and twists. Therefore, the surface roughness and the waviness of the workpiece are not good. In this paper, the effects of cutter orientation and the lead/tilt angle used to machine turbine blades with a 5-axis high speed ball end-milling were investigated to improve geometric accuracy and surface integrity. The experiments were performed using a lead/tilt angle of 15$^{\circ}$ to the workpiece with four cutter directions such as horizontal outward, horizontal inward, vertical outward, and vortical inward directions. Workpiece deflection, surface roughness and the machined surface were all measured with various cutter orientations such as cutting directions, and lead/tilt angle. The results show that the best cutting strategy for machining turbine blades with a 5-axis milling is horizontal inward direction with a tilt angle.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.53-60
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• 2002

Recently, the development of aerospace and automobile industries brought new technological challenges, related to the growing complexity of products and new geometry models. High speed machining using 5-Axis milling machine is widely used for 3D sculptured surface parts. 5-axis milling of turbine blade generates the vibration, deflection and twisting caused from thin and cantilever shape. So, the surface roughness and the waviness of workpiece are not good. In this paper, The effects of cutter orientation and lead/tilt angle in 5-Axis high speed ball end-milling of turbine blade were investigated to improve the geometric accuracy and surface integrity. The experiments were performed at lead/tilt angle $15^{\circ}$ of workpiece with four cutter directions such as horizontal outward, horizontal inward, vertical outward, and vertical inward. Workpiece deflection, surface roughness and machined surface were measured with various cutter orientations such as cutting direction, and lead/tilt angle. The results show that when 5-axis machining of turbine blade, the best cutting strategy is horizontal inward direction with tilt angle. The results show that when 5-axis machining of turbine blade, the best cutting strategy is horizontal inward direction with tilt angle.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.19-22
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• 1997

The objective of this research is to use an analytical and experimental approach to develop optimal tool geometry for high speed machining. The tool geometry parameters and cutting process have complex relationships. Until now, numerous cutting tests were needed to acquire optimal design of endmill for the purpose of high speed machining, dut to the insufficient knowledge about process in high speed machining. In order to improve the cutting ability of endmill, a model for optimal cutter shape was developed to minimize resultant cutting force by combing cutting force and wear test and surface roughness test from optimized and conventional cutter with the same cutting condition. Using various tools with different geometry, relationships between the tool geometry parameter, rake angle, clearance angle, lengh of cutter have been stuied.

• Journal of Korean Tunnelling and Underground Space Association
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• v.17 no.3
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• pp.403-413
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• 2015

This paper presents the cutter bit damage due to the rotation speed of shield TBM cutter head in the mixed ground. The efficient of cutter bits and disk cutter are very important for tunnelling in mixed ground. In particular, this research is focused on the performance of cutter bits during excavation in mixed ground which is consist of the weathered soil and rock formation. In order to carry out this research, the experimental works are prepared performed by using the scaled shield TBM cutter bits evaluation machine developed. The mixed ground is prepared considering with a scale effect of tunnel size. Three different rotation speeds of shield TBM cutter head (i.e. 2, 3, 4 rpm) are applied in the experimental work. The drag forces acting on the cutter bits are measured at each cutter bit during rotation of cutter head. It is also analysed the variation of drag forces due to the rotation speed of shield TBM cutter head. The results of this research are clearly shown that the drag forces acting on the cutter bits are jumped up at the boundary between weathered soil and rock. It is also indicated that the jamping drag forces are increased with increasing the rotation speed of the cutter head. It is found from the research that the higher rotation speed of shield TBM cutter head will be high risk in the mixed ground. It is, therefore, suggested that the use of lower rotation speed of shield TBM cutter head is recommended for reducing the cutter bit damage in practice.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2003.05a
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• pp.944-949
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• 2003

A High-speed cutter, a kind of electric tool is studied to reduce its vibration and noise. The experimental modal analysis, the operational deflection shapes(ODS) and the time domain analysis(TDA) are used in the SMS software to analyze the vibration signals from an operating high-speed cutters under steady state operating condition. The second mode and fifth m,)do of the base plate coincide with the driving frequencies of the motor, And the vibration of the wheel cover is caused by the gap between the main wheel cover and the sub wheel cover. The structural modification for the base plate was done to reduce the vibration. The effect of modification is verified through the test.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.10 s.181
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• pp.2496-2501
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• 2000

High speed ball end milling is attracting interest in the aerospace industry for the machining of complex 31) airfoil surfaces in nickel based superalloys, Experimental work is detailed on the effect of cutter orientation on tool life, cutting forces, chip formation, specific force and workpiece surface roughness, when high speed ball end milling nickel based supperalloy(lnconel 718). Dry cutting was performed using 8min diameter solid carbide cutters coated with either TiA1N or CrN for the workpiece mounted at an angle of 45˚ from the cutter axis. A horizontal downwards cutting orientation provided the best tool life with cut lengths~50% longer than for all other directions. Evaluation of cutting forces and associated spectrum analysis of results indicated that cutters employed in a horizontal downwards direction produced the least vibration.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.06a
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• pp.19-27
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• 2000

High speed machining (HSM), specifically end milling and ball end cutting, is attracting interest in the die/mold or aerospace industries for the machining of complex 3D surfaces. HSM of difficult-to-cut materials such as die/mold steels, titanium alloys or nickel based superalloys generates the concentrated thermal/frictional damage at the cutting edge of the tool and rapidly decreases the tool life. Following a brief introduction on HSM and reated aerospace or die/mold work, the paper reviews published data on the effect of cutter/workpiece orientation and cutting environments on tool performance. First, experimental work is detailed on the effect of cutter orientation on tool life, cutting forces, chip formation, specific force and workpiece surface roughness. Cutting was performed using 8 mm diameter PVD coated solid carbide cutters with the workpiece mounted at an angle of 45 degree from the cutter axis. A horizontal downwards cutting orientation proveded the best tool life with cut lengths ∼50% longer than for all other directions (horizontal upwards, vertical downwards, vertical upwards). Second, the cutting environments were investigated for dry, flood coolant, and compressed chilly air coolant cutting. The experiments were performed for various hardened materials and various coated tools. The results show that the cutting environment using compressed cilly air coolant provided better tool life than the flood coolant or the dry.

• International Journal of Precision Engineering and Manufacturing
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• v.3 no.4
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• pp.31-36
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• 2002

A continuous tool-path, that is to cut continuously with the minimum number of cutter retractions during the cutting operations, is developed in order to minimise the fluctuation of cutting load and the possibility of chipping on the cutting edge in HSM (high-speed machining). This algorithm begins with the offset procedure along the boundary curve of the sculptured surface being machined. In the of offset procedure, the offset distance is determined such that the scallop height maintains a constant roughness to ensure higher levels of efficiency and quality in high-speed machining. Then, the continuous path is generated as a kind of the diagonal curve between the offset curves. This path strategy is able to connect to neighbor paths without cutter retractions. Therefore, the minimum tool retraction tool-path can be generated And, it allows the sculptured surface incorporating both steep and flat areas to be high-speed machined.