• Title/Summary/Keyword: Milling insert

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Characteristics of the Powder Type Ag System Insert Metals Made by Ball Milling Method and Brazed Joints (볼 밀링법으로 제조된 브레이징 삽입금속 및 접합 특성)

  • 김광수;이규도;황선효
    • Journal of Welding and Joining
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    • v.20 no.1
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    • pp.47-54
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    • 2002
  • Powder type Ag system insert metals were manufactured by ball milling process. The variables of milling process such as milling media, revolution speed and powder/ball weight ratio were constant except the milling time. The milling times were selected for 24, 48 and 72 hours. The insert metals made by milling process were evaluated by performing scanning electron microscope, x-ray and DSC(differential scanning calorimetry) analysis, and further in terms of wettability test. The selected insert metals that have the good characteristics compared to commercial insert metals were applied to make the brazed joints of the steel/steel and the steel/WC superhard particles. The characterizations of those brazed joints were also conducted by microstructural observations, shear tensile tests and microhardness measurements. The results indicated that milling time of 48 hours for making powder type insert metals was the best condition showing the small amount of oxides residue, low wetting angle and stable microstructure. The brazed joints that applied the 48 hours milled insert metal were very sound condition indicating the shear tensile value of $2.29{\times}102$ MPa and the microhardness of 138VHN. Further, the amount of the porosity was appeared to be lower than that of the commercial insert metals.

Characterisrics of the Ag System Insert Metal Produced by Powder Mixing Process (분말 혼합 공정으로 만들어진 은계 삽입금속의 특성)

  • Kim, Gwang-Soo;Kim, Sang-Duck
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.9 no.2
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    • pp.311-316
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    • 2008
  • Powder type Ag system insert metals were manufactured by ball milling process. The variables of milling process were constant except the milling time. The milling times were selected for 24, 48 and 72 hours. The insert metals made by milling process were evaluated by performing scanning electron microscope, DSC(differential scanning calorimetry) analyses, spreading test and further in terms of wettability test. The selected insert metals that have the good characteristics compared to commercial insert metals were applied to make the brazed joints. The characterizations of those brazed joints were also conducted by microstructural observations. The results indicated that milling time of 48 hours for making powder type insert metals was the best condition showing the good spreadibility, low wetting angle. The brazed joints that applied the 48 hours milled insert metal were very sound condition indicating the stable microstructure in spite of containing small amount of porosity and the microhardness value of the joint was about 138VHN.

Wettability and Microstructures of Ag System Insert Metals Manufactured by Mechanical Alloying Method: (기계적 합금화방법으로 만들어진 Ag계 삽입금속의 젖음성과 미세조직)

  • Kim, Gwang-Su;No, Gi-Sik;Hwang, Seon-Hyo
    • Korean Journal of Materials Research
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    • v.11 no.12
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    • pp.1020-1027
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    • 2001
  • Powder type Ag system insert metals were manufactured by mechanical alloying method. Alloying method was the ball milling process using zirconia ball media, and all alloying variables were constant except the milling time. The milling times were selected 24, 48 and 72 hours. The insert metals made by milling method were observed using scanning electron microscope and x-ray analyses. And also, the evaluation of wettability and microstructures of the insert metals were conducted to investigate the characteristics of the brazed joint. The wettability of the insert metals made by milling of 48 hours, was the best condition. And the insert metals contained Cd shows good wettability, however, there was the oxides residue on the brazing test specimen. The microstructures of the manufactured and the commercial insert metals were almost same displaying the Cu- rich proeutectic and Ag-rich eutectic. Further, there were some porosities. The 48 hours alloyed insert metal was exhibited the most sound brazed joint without containing porosity due to the superior wettability and good alloying condition.

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A Study on Machining Characteristics of Single-insert and Multi-insert Face Milling (단인과 다인 정면밀리의 가공특성에 관한 연구)

  • Kim, S.I.;Lee, W.R.;Kim, T.Y.
    • Journal of the Korean Society for Precision Engineering
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    • v.12 no.4
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    • pp.19-27
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    • 1995
  • Face milling is required to study cutting process with a view of multipoint cutter. This experimental study mainly deals with the single and multi-insert cutting characteristics using coated tool. Because metal cutting of the single and multi-insert has a large relation to the improvement of productivity, the economic cutting process can be achieved by the analysis of proper metal cutting mechanism. Therefore, machining characteristics of face molling in this paper has been studied by investigating the role of different insert number which is concerned with mean cutting force, the RMS values of AE(acoustic emission) signal, tool life and surface roughness in milling SS 41 and SUS 304. The cutting force and AE signal are monitored to make an analysis of cutting process. The surface roughness of the specimens machined by inserts of different numbers is measured at different speeds, feeds and depth of cut. The width of flank wear is also observed.

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Study on the development of multi-tasking 5-axis machining for insert type milling cutter (인서트형 밀링커터의 복합5축가공 기술개발에 관한 연구)

  • 황종대;정윤교
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2004.04a
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    • pp.21-26
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    • 2004
  • This research presents a modeling and a manufacturing method of insert type milling cutters such as face cutter, flat endmill and ball endmill. The methods introduced in this paper adopts the multi-tasking 5-axis machining that is increasing machining accuracy of holder and position accuracy of bolting points. So this can be used in the basic document of the total package program that involves modeling and manufacturing module in various insert cutters.

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A Study on Machining Characteristics of Face Milling Using Coated Tool (코팅공구를 사용한 Face Milling의 가공특성에 관한 연구)

  • 이위로;김성일;김태영
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 1993.10a
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    • pp.106-111
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    • 1993
  • This experimental study mainly deal with the single and multi-insert cutting characteristics using coated tool. Because metal cutting of the single and multi-insert has a large relation to the improvement of productivity, the economic cutting process can be achieved by the analysis of proper metal cutting mechanism. Therefore, machining characteristics of face milling in this paper has been studied by investigating the role of different insert number which is concerned with mean cutting force, the RMS values of AE(acoustic emission) signal, tool life and surface roughness in milling SS 41 and SUS 304.

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Improvement of the Surface Roughness by Changing Chamfered Angle of the Insert in Face Milling (정면밀링가공에서 인서트의 챔퍼각 변화에 의한 표면거칠기 향상)

  • Kwon, Won-Tae;Lee, Seong-Sei
    • Journal of the Korean Society for Precision Engineering
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    • v.18 no.7
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    • pp.155-160
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    • 2001
  • A milling process with 45 degree chamfered inserts produces a perfect flat surface only in theory. It is due to many unwanted factors including thermal effect, dynamic effect, the problem of the controller used and the problem of accuracy of the machine tool. In this study, introduced is a method to improve the surface roughness by redesigning of the chamfer angle of the insert, which traditionally has been 45 degree. First, the relationship between the fixed machine coordinate and the relative coordinate on the insert is derived. This transfer matrix is used to determine the new insert angle to maximize the flatness of the machined surface. A newly designed insert is manufactured, and used to carry out the experiment. It is proved that she insert designed by the proposed method produced a much flatter surface than a traditional one.

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Prediction of Cutting Forces for the Chip Breaker Insert in Milling (밀링용 칩 브레이커 인서트의 절삭력 예측)

  • 김국원;이우영;신효철
    • Transactions of the Korean Society of Mechanical Engineers
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    • v.17 no.11
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    • pp.2664-2675
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    • 1993
  • In this paper, the effects of chip breaker configuration on cutting forces for various cutting conditions are investigated and a method for predicting cutting forces effectively for chip breaker insert in milling is described. Based on the shear plane model and the relevant equations already existing for the relation among the parameters, the method makes use of the analytic geometric approach considering the configuration of cutting too by a 3-dimensional coordinate transformation matrix. The groove type chip breaker insert is modeled to be a double rake insert, represented by the first radial rake angle, the second radial rake angle and the length of land, and the program analyzing the cutting forces is developed. The program capability is verified by comparing the results with the experimental ones for a single cutter; and in case of primary cutting forces, the results of simulation and experiments agree very well showing 2%~16.7% difference within the feed rate range investigated.

A Study on Detection of Tool Wear by Cutting Signal Measurements in Multi-insert Face Milling (정면밀링시 절삭신호측정에 의한 공구마모 검출에 관한 연구)

  • 김성일
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.6 no.4
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    • pp.124-129
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    • 1997
  • The experimental investigation is mainly focused to detect tool wear by cutting signal measurements in multi-insert face milling SS 41 and STS 304. This research have investigated the effects on the insert number, which has relationship with mean-cutting force. AE(acoustic emission) signal, tool life and surface roughness in machining SS41 and STS 304. The cutting force and AE signal are monitored to analyse the cutting process, The surface roughness of the specimens machined by TiN coated tool with the various insert numbers measured at various cutting speeds, feed rates and depths of cut, The width of flank wear is also observed.

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A Study on Geometric Definition and 5-Axis Machining of End Mill with Insert Tip (Insert Tip용 End Mill 공구의 형상정의와 5-축 가공에 관한 연구)

  • 조현덕;박영원
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.11 no.6
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    • pp.1-9
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    • 2002
  • This study describes the geometric characteristics and the 5-axis machining method in order to make end mill cutter coming with insert tips. End mill geometry is consisted of flute part and insert tip part. Flute part modeled by using ruled surfaces with constant helix angle, and insert tip part modeled by rectangular planes containing tapped hole of specified direction in its center. In this study, the modeled insert tip part considered both of a radial rake angle and a axial rake angle, because they were important cutting conditions. In order to machining the virtual end mill defined from geometric characteristics, we programmed a special software to machining the end mill considered in this study. This software can generate NC-codes about following processes, end milling or ball end milling of flute part end milling of rectangular plane, centering of hole, drilling of hole, and tapping of hole. Ant sampled end mills were modeled and machined on 5-axis CNC machining center with two index tables. Since machined end mills were very agreeable to designed end mills, we saw that the method proposed in this study can be very useful for manufacturing of end mill body with insert tip.