• Title/Summary/Keyword: Micro tool wear

Search Result 97, Processing Time 0.021 seconds

Machining of Micro-scale Shapes using Micro-EDM Process (Micro-EDM 공정을 이용한 미세 형상 가공)

  • 김영태;박성준;이상조
    • Journal of the Korean Society for Precision Engineering
    • /
    • v.20 no.9
    • /
    • pp.109-117
    • /
    • 2003
  • With development of high advanced technologies and skills, micro machining techniques also are being more functional and smaller. Some of the recently developed micro machining technologies are micro drilling, micro EDM, WEDG, LBM, micro milling, micro UVM etc. In these micro machining techniques, Micro -EDM is generally used for machining micro holes, pockets, and micro structures in difficult-cut-materials. For machining micro structures, first of all, tool electrode should be fabricated by WEDG process. In micro-EDM, parameters such as peak current, pulse width, duration time are very important to fabricate the tool electrode and micro structures. Developed experimental equipments are composed of RLC circuit with PWM. In this paper, using developed micro EDM machine, the characteristics of micro electro discharge machining are investigated at micro holes, slot, and pocket machining etc. Also the trends of tool wear are investigated in case of hole and slot machining.

Micro/Meso-scale Shapes Machining by Micro EDM Process

  • Kim Young-Tae;Park Sung-Jun;Lee Sang-Jo
    • International Journal of Precision Engineering and Manufacturing
    • /
    • v.6 no.2
    • /
    • pp.5-11
    • /
    • 2005
  • Among the micro machining techniques, micro EDM is generally used for machining micro holes, pockets, and micro structures on difficult-cut-materials. Micro EDM parameters such as applied voltage, capacitance, peak current, pulse width, duration time are very important to fabricate the tool electrode and produce the micro structures. Developed micro EDM machine is composed of a 3-axis driving system and RC circuit equipped with pulse generator. In this paper, using micro EDM machine, the characteristics of micro EDM process are investigated and it is applied to micro holes, slots, and pockets machining. Through experiments, relations between machined surface and voltages and between MRR and feedrate are investigated. Also the trends of tool wear are investigated in case of hole and slot machining.

Diamond micro-cutting of the difficult -to -cut materials using Electrolysis (전기분해를 이용한 난삭재의 다이아몬드 미세가공)

  • 손성민;손민기;임한석;안중환
    • Proceedings of the Korean Society of Precision Engineering Conference
    • /
    • 2000.11a
    • /
    • pp.951-954
    • /
    • 2000
  • This paper presents a new cutting method, i.e. diamond cutting, aided by electrolysis, in order to cut ferrous materials with diamond tools. Diamond cutting is widely applied in manufacturing ultraprecision parts such as magnetic disk, polygon mirror, spherical/non-spherical mirror and copier drum, etc. because of the diamond tool edge sharpness. In general, however, diamond cutting cannot be applied to cutting steels, because diamond tools wear excessively in cutting iron based materials like steel due to their high chemical interaction with iron in high temperature. In order to suppress the diffusion of carbon from the diamond tool and to reduce increase of cutting force due to size effect, we attempt to change chemically the compositions of iron based materials using electrolysis in a limited part which will be soon cut. Through experiments under several micro-machining and electrolysis conditions, cutting using electrolysis, compared to conventional cutting, was found to result in a great decrease of the cutting force, a better surface and much less wear tool.

  • PDF

A Comparative Study of Transistor and RC Pulse Generators for Micro-EDM of Tungsten Carbide

  • Jahan, Muhammad Pervej;Wong, Yoke San;Rahman, Mustafizur
    • International Journal of Precision Engineering and Manufacturing
    • /
    • v.9 no.4
    • /
    • pp.3-10
    • /
    • 2008
  • Micro-electrical discharge machining (micro-EDM) is an effective method for machining all types of conductive materials regardless of hardness. Since micro-EDM is an electro-thermal process, the energy supplied by the pulse generator is an important factor in determining the effectiveness of the process. In this study, an investigation was conducted on the micro-EDM of tungsten carbide (WC) to compare the performance of transistor and resistance/capacitance (RC) pulse generators in obtaining the best quality micro-hole. The performance was measured by the machining time, material removal rate, relative tool wear ratio, surface quality, and dimensional accuracy. The RC generator was more suited for minimizing the pulse energy, which is a requirement for fabricating micro-parts. The smaller-sized debris formed by the low-discharge energy of RC micro-EDM could be easily flushed away from the machined zone, resulting in a surface free of burrs and resolidified molten metal. The RC generator also required much less time to obtain the same quality micro-hole in WC. Therefore, RC generators are better suited for fabricating micro-structures, producing good surface quality and better dimensional accuracy than the transistor generators, despite their higher relative tool wear ratio.

Micro Machining of Titanium Alloy Using Polycrystalline Diamond Tools (PCD 공구를 이용한 티타늄 합금의 미세 가공)

  • Moon, In Yong;Kim, Bo Hyun
    • Journal of the Korean Society for Precision Engineering
    • /
    • v.30 no.3
    • /
    • pp.284-291
    • /
    • 2013
  • Micro cutting of titanium alloy by polycrystalline diamond (PCD) tools was studied. Micro electro discharge machining (MEDM) was used to fabricate customized micro shaping tools from PCD blank. The tool was used to machine micro grooves on Ti alloy and the effects of depth of cut and machining length on tool wear, burr and surface roughness were studied. The shaping tool has cutting edge of a few ${\mu}m$. The crater size of the tool surface was increased with increasing capacitance of EDM machining conditions, which was used to control the surface roughness of the machined micro grooves.

State Monitoring using AE Signal in Micro Endmilling (마이크로 엔드밀링에서 음향방출 신호를 이용한 상태감시)

  • 정연식;강익수;김전하;강명창;김정석;안중환
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
    • /
    • 2004.10a
    • /
    • pp.334-339
    • /
    • 2004
  • Ultraprecision machining and MEMS technology have been taken more and more important position in machining of microparts. Micro endmilling is one of the prominent technology that has wide spectrum of application field ranging from macro parts to micro products. Also, the method of micro-grooving using micro endmilling is used widely owing to many merit, but has problems of precision and quality of products due to tool wear and tool fracture. This investigation deals with state monitoring using acoustic emission(AE) signal in the micro-grooving. Characteristic evaluation of AE raw signal, AE hit and frequency analysis for state monitoring is also presented in the paper.

  • PDF

The Cutting Process Monitoring of Micro Machine using Multi Sensor (멀티센서를 이용한 마이크로 절삭 공정 모니터링)

  • Shin, B.C.;Ha, S.J.;Kang, M.H.;Heo, Y.M.;Yoon, G.S.;Cho, M.W.
    • Transactions of Materials Processing
    • /
    • v.18 no.2
    • /
    • pp.144-149
    • /
    • 2009
  • Recently, the monitoring technology of machining process is very important to improve productivity and quality in manufacturing filed. Such monitoring technology has been performed to measurement using vibration signal, acoustic emission signal and tool dynamometer. However, micro machining is limited small-scale parts machining because micro tool is very small and weakness to generate signal in micro machining process. Therefore, this study has efficient sensing technology for real monitoring system in micro machine that is proposed to supplement a disadvantage of single-sensor by multi sensor. From experimental result, it was evaluated tool wear and cutting situation according to repetitive slot cutting condition and changing cutting condition, and it was performed monitoring spindle rpm and condition according to compare acceleration signal with current signal.

Micro-machining of Glass Air Hole using Ultrasonic Machining (초음파 가공에 의한 미세 에어홀 가공 기술)

  • 김병희;전성건;남권선;김헌영;전병희
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
    • /
    • 2004.04a
    • /
    • pp.48-52
    • /
    • 2004
  • Ultrasonic machining is effective for machining of extreme hard and brittle materials, including glass, ceramic, carbide, graphite. The major machining principle involves the direct hammering as well as the impact of abrasive panicles on the workpiece. Also, it involve cavitation erosion. The general workpiece is flat side. This study attempted micro hole machining of a curved surface of glass tube. Ultrasonic machining is fault of the slow machining speed. An experiment does and got 16 seconds validity machining time as increasing the processing speed. Moreover, entrance crack and surface roughness was similar both machining speed is slow and fast. Several micro hole of glass tube machined using one micro tool, but tool wear is infinitesimal.

  • PDF

Modeling of Cutting Parameters and Optimal Process Design in Micro End-milling Processes (마이크로 엔드밀링 공정의 절삭계수 모델링 및 최적 공정설계)

  • Lee, Kwang-Jo;Chung, Sung-Chong
    • Journal of the Korean Society of Manufacturing Technology Engineers
    • /
    • v.18 no.3
    • /
    • 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.

  • PDF