• Journal of the Korean Society for Precision Engineering
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• v.11 no.2
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• pp.182-188
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• 1994

This expermintal study is intended to investigate he development of flank wear in turning os SUS304 which is used in industrial applications and is acknowledged as a machining difficult material. In cutting process, change of velocity, change of feed, and change of depth of cut were investigated about the effect of flank wear, and slenderness ratio is also investigated. The variations of unit cutting force with the change of rake angle and the change of uncut chip area are observed. The friction angles are calculated for the change friction force and observed. The friction angles are calculated for the change friction force and normal forcd on the different rake angles. From this experimental study, the following results can be said. 1. Under the high cutting speed condition, the flaank wear is affected by the feed and depth of cut, but the influence of feed and depth of cut to the flank wear is reduced when the velocity is low. 2. The smaller slenderness ratio is, the shorter the tool life results in high cutting speed, and the lower cutting speed is, the lower the effect of slenderness ratio to the flank wear is. 3. Using the characteristics of force-RMS, the flank wear of a tool can be detected. There are almost no differences between the RMS characteristics of cutting force and feed force.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.7
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• pp.857-864
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• 2013

A laser machining process has been applied in many manufacturing fields and it provides an excellent energy control for treating materials. However, a heat effect during laser machining can deteriorate material properties. Specifically, a thermally induced stress can be a problem in laser-machined structures on a metal surface. In this study, temperature and stress on cold-rolled carbon steel sheet machined with laser hole drilling were explored in an experimental approach and a numerical method. Stresses by temperature gradients inside the materials were generated in fast cooling. The stresses were measured by using a hole-drilling method and the material properties of carbon steel (SCP1-S) were obtained in the experiment. It was found that the stress predicted from the numerical analysis was in agreement with the stresses measured by using the hole-drilling method. The analysis can be applied for evaluating structure characteristics machined with a laser.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.12
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• pp.1285-1289
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• 2012

This study has been focused on application of ELID lapping process for mirror-surface machining of sapphire wafer. Sapphire wafer is a superior material with optic properties of high performance as light transmission, thermal conductivity, hardness and so on. High effective surface machining technology is necessary to use sapphire as various usages. The interval ELID lapping process has been set up for lapping of the sapphire material. According to the ELID lapping experimental results, it shows that 12.5 kg of load for lapping is most pertinent to ELID lapping. the surface of sapphire can be eliminated by metal bonded wheel with micron abrasives and the surface roughness of 60 nmRa can be gotten using grinding wheel of 2,000 mesh in 4.5 um, depth of cut. In this study, the chemical experiments after ELID grinding also has been conducted to check chemical reaction between workpiece and grinding wheel on ELID grinding process. It shows that the chemical reaction has not happened as the results of the chemical experiments.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.1
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• pp.85-91
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• 2013

The machinability of wear-resistible tungsten carbides and the tool wear behavior in machining of V30 and V50 tungsten carbides using PCD (Poly Crystalline Diamond) cutting tool was investigated to understand machining characteristics. This material is one of the difficult-to-cut materials in present, but their usage has been already broadened to every commercial applications such as mining tools, and impact resistant tools etc. Summary of the results are as follows. (1) Tool wear progression of PCD tools in turning of wear-resistible tungsten carbides were observed specially fast in primary cutting distance within 10m. (2) Three components of cutting resistance in this research were different in balance from the ordinary cutting such as that cutting of steel or cast iron. Those were expressed large value by order of thrust force, principal force, feed force. (3) If presume from viewpoint of high efficient cutting within this research, a proper cutting speed was 15m/min and a proper feed rate was 0.1mm/rev. In this case, it was found that the tool life of PCD tool was cutting distance until 230m approximately. (4) In cutting of wear-resistible tungsten carbides such as V30 and V50, it was recognized that the tool wear rate of V30 was very fast as compared with V50. (5) When the depth of cut was 0.1mm, there was no influence of the feed rate on the feed force. And the feed force tended to decrease as the cutting distance was long, because the tool was worn and the tool edge retreated. (6) It was observed that the tungsten carbides were adhered to the flank.

• Transactions of the Korean Society of Mechanical Engineers
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• v.11 no.1
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• pp.74-81
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• 1987

The orthogonal cutting method of the nodular graphite cast iron in the lathe turning, whose structure were formulated under two kinds of annealing conditions, has been experimentally studied and the results investigated. The various characteristics of machinabilities of the nodular cast iron, depending upon its structure, have been obtained from the results as follows. (1) As depth of cut increases, the shearing strain decreases and tend gradually to increase with increase of ferrite matrix. (2) As depth of cut increases, the shearing stress slightly decreases for P$_{1}$, but it tends to increase for both of P$_{2}$ and P$_{3}$ under the same condition. The annealing effect in the process of light cutting was found to be greater than heavy cutting. (3) The cutting energy slightly decreases with the increassing of the depth of cut, and the effect of decreasing the cutting energy by the annealing is higer the light cutting than the heavy cutting. (4) The cutting equations as follow. P$_{1}$ : 2.phi.+1.58(.betha.-alpha.)=92 deg. P$_{2}$ : 2.phi.+1.40(.betha.-alpha.)=84 deg. P$_{3}$ : 2.phi.+1.37(.betha.-alpha.)=82 deg. (5) The machining constants for P$_{1}$, P$_{2}$ and P$_{3}$ which are the test-pieces in this study and classified according to the containing quantity of ferrite matrix given respectively in 78deg., 70 deg., and 68 deg. From these it can be known that the machining constants slightly decreases with increasing of the quantity of ferrite matrix contained in the nodular graphite cast iron.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.2
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• pp.44-49
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• 2017

In this study, the cutting conditions of moving speed, number of main axial revolutions, etc. are changed for the chrome molybdenum steel (SCM415) material and carbide ball end mill tool to study the changes for processing intensity in the cutting process. The results that confirm the intensity of the measured value of the specimen for SCM415 display the intensity with an average 1.0667 HrC. After the fact cutter, it was able to confirm the average intensity of 8.3815 HrC. In addition, the intensity value after image processing may determine the average intensity survey value of 5.8690 HrC and the different intensity values with image processing after face cutting are shown for an average of ${\pm}2.5125HrC$. The different value of intensity with the specimen and image processing is confirmed for an average of 4.8024 HrC. The results of comparing the intensity following the number of main axial revolutions and moving speed show that the intensity is highest for 3,000 rpm and F200, and lowest for 4,000 rpm and F200.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.7
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• pp.2118-2133
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• 1996

A preform is designed by the backward tracing scheme of the rigid-plastic finite element method(FEM) for net-shape shell nosing components without machining after forming. The current process of the shell nosing requires cost-consuming machining to produce final products. Here, the backward tracing scheme of the rigid-plastic FEM, a novel method for preform design of metal forming processes, derives a sound preform for net-shape shell nosing product. The current process is simulated by the rigid-plastic finite element analysis to check the metal flow involved in the forming with a trial preform and its modified preform. The two preforms are found to be inadequate for net-shape shell nosing product. The first application of the back ward tracing scheme derives a preform producing a not-shape shell nosing product. The first application of the backward tracing scheme derives a preform producing a net-shape product numerically, but it is difficult to be formed economically as a preform. Thus an improved preform is designed by the badkward tracing scheme, which is suitable for net-shape manufacturing of the shell nosing components in view of economy of production and forming characteristics of the product. The preform in the current process and a modified preform are confirmed by a series of experiments and the results give the same deformation with the numerical ones. Finally the newly designed preform by the FEM was experimentally proved to be adequate in obtaining net-shape products.

• 제어로봇시스템학회:학술대회논문집
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• 1992.10a
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• pp.537-540
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• 1992

This paper presents Samsung CNC (Computer Numerical Controller) system with an intel 80486/487 as the main CPU and a 32 bit floating point DSP(Digital Signal Processor) TMS320C30 as the motion control CPU. The Samsung CNC system diverse user-frienly characteristics such as multi-tasking, powerful menu system, internal PLC system, and 2/3 dimensional graphics in wire and solid mode. The main CPU executes central processing program, user interface program, interpreter, BMI, etc while the motion control CPU carries out some interpolations, acceleration/deceleration, and PID control algorithm with feedforward terms. Complex interpolations except linear and circular ones are performed on the main control CPU. The experimental results for the circular interpolation under linear acceleration/deceleration shows that the proposed CNC system can be widely used in controlling machining centers with good machining accuracy.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.12
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• pp.1303-1312
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• 2013

We report an ultra-precision lathe designed to machine micron-scale features on a large-area roll mold. The lathe can machine rolls up to 600 mm in diameter and 2,500 mm in length. All axes use hydrostatic oil bearings to exploit the high-precision, stiffness, and damping characteristics. The headstock spindle and rotary tooling table are driven by frameless direct drive motors, while coreless linear motors are used for the two linear axes. Finite element method modeling reveals that the effects of structural deformation on the machining accuracy are less than $1{\mu}m$. The results of thermal testing show that the maximum temperature rise at the spindle outer surface is approximately $0.5^{\circ}C$. Finally, performance evaluations of the error motion, micro-positioning capability, and fine-pitch machining demonstrate that the lathe is capable of producing optical-quality surfaces with micron-scale patterns with feature sizes as small as $20{\mu}m$ on a large-area roll mold.

• Tribology and Lubricants
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• v.34 no.1
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• pp.23-32
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• 2018

Coupling is a mechanical component that transmits rotational force by connecting two shafts. Curvic coupling is widely used in high-performance systems because of its excellent power transmission efficiency and easy machining. However, coupling applications change dynamic behavior by reducing the stiffness of an entire system. Contact surface stiffness is an important parameter that determines the dynamic behavior of a system. In addition, the roughness profile of a contact surface is the most important parameter for obtaining contact stiffness. In this study, we theoretically establish the process of contact and bending stiffness analysis by considering the rough surface contact at Curvic coupling. Surface roughness parameters are obtained from Nayak's random process, and the normal contact stiffness of a contact surface is calculated using the Greenwood and Williamson model in the elastic region and the Jackson and Green model in the elastic-plastic region. The shape of the Curvic coupling contact surface is obtained by modeling a machined shape through an actual machining tool. Based on this modeling, we find the maximum number of gear teeth that can be machined according to the contact angle. Curvic coupling stiffness is calculated by considering the contact angle, and the calculation process is divided into stick and slip conditions. Based on this process, we investigate the stiffness characteristics according to the contact angle.