• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.4
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• pp.57-63
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• 2011

The aim of this study is to analyze turning process using commercial FEM simulation code. Various simulation models of orthogonal cutting process for 3 layers of metallic material have been simulated and analyzed. The workpiece material used for the orthogonal plane-strain metal cutting simulation consists of three layers, which are Allow Tool Steel, Aluminum and Stainless Steel. The finite element model is composed of a deformable workpiece and a rigid tool. The tool penetrates through the workpiece at a constant speed and constant feed rate. As an analytical result, detailed cutting temperature, strain, pressure, residual stress for both a tool and each layer of workpiece were obtained during the turning process. It has been closely observed that the chip flow curve deforms continuously.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.10a
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• pp.211-215
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• 2000

A new methodology is presented to evaluate material properties at high strain rates and high temperatures based on orthogonal metal cutting experiments and FEM simulations. Average strain rate and average temperature found in the deformation zone are computed and flow stress data at these conditions are modified until cutting forces calculated in simulations match those determined in experiments. Material properties obtained from this method were verified by additional metal cutting simulations. Derivation from cutting forces measured in experiments was less than 10%. The feasibility of tool design using FEM simulations is also demonstrated.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.5
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• pp.130-136
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• 2001

Generally, a metal slitting saw is plain milling cutter with thickness less than 3/16 inch. This is used for cutting a workpiece that high dimensional accuracy and surface finish is necessary. A small thin milling cutter like a metal slitting saw is useful for machining a narrow groove. In this case, built up edge(BUE) is severe at each tooth and affects the surface integrity of the machined surface and tool wear. It is well known that tool geometry and cutting conditions are decisive factors to remove BUE. In this paper, we optimized the geometry of the milling cutter and selected cutting conditions to remove BUE by the experimental investigation. The experiment was planned with Taguchi method based on the orthogonal array of design factors such as coating, rake angle, number of tooth, cutting speed, feed rate. Response table was obtained from the number of built-up edge generated at tooth. The optimized tool geometry and cutting conditions could be determined through response table. In addition, the relative effect of factors was identified bh the analysis of variance (ANOVA). Finally, coating and cutting speed turned out important factors for BUE.

• Nuclear Engineering and Technology
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• v.52 no.5
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• pp.1043-1050
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• 2020

Radioactive aerosols are produced during the cutting of contaminated and activated metals. They must be collected and removed by a high-performing filtration system before releasing to the environment from the decommissioning workplace. The filtration system requires regular replacement to ensure the sufficient removal of radioactive aerosols because its filtration efficiency gradually decreases. This study evaluates the efficiency and lifetime of filters while cutting metals by using a plasma arc cutter. Particularly, this study considers the aerodynamic diameter distribution of number and mass concentrations for aerosols from 6 nm to 10 ㎛ when evaluating the performance of filters. After 20 time reuses for cutting operation performed in a cutting chamber, the removal efficiency is reduced from over 99 to below 93% at 2 ㎛. The results are used to analyze the lifetime of filters, the frequencies of their replacements, and impact on internal radiation dose.

• International Journal of Precision Engineering and Manufacturing
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• v.7 no.1
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• pp.18-23
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• 2006

Cutting by a high speed laser cutting machine is one of most effective technologies to improve productivity. This paper has presented the cutting characteristics and optimal cutting conditions in a high speed feeding type laser cutting machine by using Tacuchi method in the design of experiment. An L9(34) orthogonal array is adopted to study the effect of adjustment parameters. The adjustment parameters consist of cutting speed, laser power, laser output duty and assistant gas pressure. The surface roughness of sheet metal is regarded as a quality feature. Analysis of variance is performed in order to evaluate the effect of adjustment parameters on the quality feature of laser cutting process.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.5
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• pp.498-506
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• 2009

An experimental study was performed to select cutting parameters for better quality-products in hard metals such as steels. Usually, a hard metal can be cut with a rotary cutting knife and the process provides a good cutting quality result. However, the cutting machine is much sensitive in cutting conditions because of its complicated mechanism. By this reason, careful processing conditions must be taken to improve the quality of the products. This experimental study for better quality products with a rotary cutting knife was carried out with two main factors; cutting speeds and cutting and pooling forces. A two-dimensional profile measuring instrument is used to evaluate its cutting faces and the effects of processing factors are analyzed by a commercial software.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.6
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• pp.77-83
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• 2004

Cutting by a high speed laser cutting machine is one of most effective technologies to improve productivity. This paper has studied to obtain the cutting characteristics and optimal cutting conditions in a high speed feeding type laser cutting machine by Tacuchi method in design of experiments. A Lf(34) orthogonal array is adopted to study the effect of adjustment parameter. The adjustment parameters consist of cutting speed, laser power, laser output duty and assistant gas pressure. And the quality feature is selected as surface roughness of sheet metal. Variance analysis is performed in order to evaluate the effect of adjustment parameters on the quality feature of laser cutting process.

• Transactions of the Korean Society of Mechanical Engineers
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• v.5 no.4
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• pp.338-346
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• 1981

Honing, lapping, polishing and superfinishing are applied for a precision machining to finish the metal surface, but these precision machining are micro-cutting by hard and micro-abrasive grains. Frictional machining is the new method to finish mirrorlike surface without using those abrasive grains. The frictional machining produces high pressure and high temperature instantly by compressing a tool material against the metal surface in sliding motion. The metal surface is given plastic deformation and plastic flow by the above mentioned frictional motion, but the surface roughness of the metal surface is influenced by physical and chemical reaction in surrounding atmosphere. Therefore, the atmosphere around the metal optimum atmosphere in the frictional machining. The part 1 of the study was performed in liquid atmospheres. Diesel oil, lubricant, grease, lard oil, bean oil and cutting fluid were used as such atmospheres. Medium carbon steel SM 50 C was used as a workpiece and ceramic tip was applied as a frictional tool. The result of the experiment showed characteristic machining conditions to generate the best surface roughness in each atmospheres.

• Journal of the Korean Society of Safety
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• v.18 no.3
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• pp.22-28
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• 2003

This study proposes the construction of chaos simulator for cutting characteristics evaluation of non-ferrous metals. Also this paper aims to find the optimal cutting conditions of diamond turning machine by measuring surface form and roughness to perform the cutting experiment of non-ferrous metals, which are aluminum, with diamond tool. As well, according to change cutting conditions such as fled rate, using diamond turning machine to perform cutting processing, by measuring cutting force and surface roughness and according to cutting conditions the aluminum about cutting properties. Trajectory changes in the attractor indicated a substantial difference in fractal characteristics. Constructed chaos simulator in this study can be used for cutting characteristics evaluation of non-ferrous metals.

• Journal of the Korean institute of surface engineering
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• v.34 no.4
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• pp.337-341
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• 2001

TiN coating of high speed end mill is recently generalized. The study of coating layer using ion plating is mainly about the coating method and the why of the longer life of coated tools. In CNC machning process, metal cutting isn't carry out until the tools including the end-mill and so on are fractured. Namely, it is difficult precision processing when the cutting force of the cutting tool is near the limit the fracture cutting force. So, the estimate of the life by wear and fracture is important. Therefore, this study is about the method to estimate the capacity of the coating layer in relation to the tendency of cutting force and the influence of the cutting capacity of coated end-mill by the condition N2, Ar, temperature. The cutting length is in inverse proportion to the cutting force ratio. So, the life of the TiN coated end mill can be predicated by the ratio of the increase of the cutting force.