• Journal of the Korean Society for Precision Engineering
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• v.29 no.3
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• pp.279-288
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• 2012

The material removal mechanism in machining is significantly affected by the cutting edge geometry. Its effect becomes even more substantial when the depth of cut is relatively small as compared to the characteristic length which represents the shape and size of the cutting edge. Conventionally, radius or focal length has been employed as the characteristic length with the assumption that the shape of cutting edge is round or parabolic. However, in reality, there could be various ways to determine the radius or focal length even for the same tool edge profile, depending on the region to be considered as cutting edge in the measured profile and the constraints to be set in constructing the best fitted circle or parabola. In this regard, the present study proposes various models to determine the characteristic length in terms of radius or focal length. Their physical compatibility are validated by carrying out 2D orthogonal cutting experiments using inserts with a wide range of characteristic length ($30{\sim}180\;{\mu}m$ in terms of radius) and then by investigating the correlation between the characteristic length and the cutting forces. Such validation is based on the common belief that the larger the characteristic length is, the blunter the cutting edge is and the higher the cutting forces are. Interestingly, the results showed that the correlation is higher for the radius or focal length obtained with a constraint that the center of best fitted circle or the focus of the best fitted parabola should be on the bisectional line of the wedge angle of tool.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.8
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• pp.62-69
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• 2010

Internal lathe machining with a boring bar is weak with respect to vibration because the bar is long and slender. Therefore, it is important to study the dynamic characteristics of a boring bar. The purpose of this study was to identify the effects of overhang and cutting conditions on the dynamic response characteristics of a boring bar. For an efficient experiment, an $L_g(3^3)$ orthogonal array was applied and the results were quantitatively analyzed by ANOVA. Overhang, feed per revolution, and depth of cut were selected as independent variables. Meanwhile, dynamic stiffness, damping ratio, damping coefficient, and acceleration were chosen as dependent variables. The vibration signal was obtained from an accelerometer attached to the boring bar, followed by visualization by a signal analyzer. The effect of overhang was found to have a significant effect on the dynamic stiffness, damping ratio, and damping coefficient, but the other variables did not. As the length of the overhang increased, the dynamic stiffness decreased and the damping ratio increased. In addition, the damping coefficient increased until the length of the overhang was 4D (where D is the shank diameter), after which it remained constant. The acceleration decreased until the overhang length was 4D, and then increased sharply when the overhang was increased further. From these results, the behavioral trend of the damping characteristics changed when its overhang length was 4D. Consequently, there is a critical point that the dynamic characteristics of boring bar change.

• Journal of the Korean Society for Precision Engineering
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• v.6 no.1
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• pp.45-51
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• 1989

In metal cutting various types of chips are produced in consequence of cutting conditions. According to the type of chips the cutting mechanism is to be changed. Most of the cutting theory is based on the continuous chip because of its convenient analysis, but the occurrence of the saw-toothed chip depends upon the workpiece and/or the cutting conditions, one of which is titanium alloy used widely. Nowadays titanium alloys are used widely with the rapid development of aerospace structural engineering application, whereas the theory of cutting mechanism has not been established yet, and the formatting process has not been understood satisfactorily, either. Unfortunately several misconceptions, conflicting statements and statements needing further clarifi- cation are also found. In this paper an attempt is made to clarify the formation process of saw-toothed chips which are to be produced during the orthogonal cutting process of titanium alloys. They were machined at low speed to avoid the rapid tool wear. We observed the SEM-photographs of chips taken at the quick-st- opping device. It is hoped that a rational model of the mechanics of cyclic chip formation can be developed. The results obtained are as follows. 1. When a saw- toothed chip is formed, the shear band begins at the primary shear zone and trans- fers to the free surface, so that a segment is produced and it is completed by upsetting between the formatting segment and the formatted segment. 2. As the rake angle or the clearance angle increases in the machining of the titanium alloy, the chip approaches to that of the continous type. 3. When the rake angle and the clearance angle are increased the shear energy and the unit friction energy decrease, which shows the same aspect as that of the continuous chip.

• International Journal of Precision Engineering and Manufacturing-Green Technology
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• v.5 no.5
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• pp.583-591
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• 2018

Tool-chip adhesion impacts on cutting performance significantly, especially in finish cutting process. To promote cutting tools' anti-adhesion property, the concave micro-grooves texture (MGT) and convex volcano-like texture (VLT) were fabricated separately on lathe tools' rake faces by laser surface texturing (LST). Various orientations of MGT and different area densities (9% and 48%) and regions (partial and full) of VLT were considered in textured patterns designing. The following orthogonal cutting experiments, machining of aluminum alloy 5038, analyzed tools' performances including cutting force, cutting stability, chip shape, rake face adhesion and abrasion. It indicated that under dry finish cutting conditions, MGT contributed to cutting stability and low cutting forces, meanwhile friction and normal force reduced by around 15% and 10%, respectively with a weak correlation to the grooves' orientation. High density VLT tools, on the other hand, presented an obvious anti-adhesion property. A $5{\mu}m$ reduction of crater wear's depth can be observed on textured rake faces after long length cutting and textured rake faces presented half size of BUE regions comparing to the flat tool, however, once the texture morphologies were filled or worn, the anti-adhesion effect could be invalid. The bearing ratio curve was employed to analysis tool-chip contact and durability of textured surfaces contributing to a better understanding of anti-adhesion and enhanced durability of the textured tools.