• Journal of the Korean Society for Precision Engineering
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• v.29 no.12
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• pp.1272-1278
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• 2012

The micro barrier rip array structures have been applied in a variety of areas including as privacy films, micro heat sinks, touch panel and optical waveguide. The increased aspect ratio (AR) of barrier rip array structures is required in order to increase the efficiency and performance of these products. There are several problems such as burr, defect of surface roughness and deformation and breakage of barrier rip structure with machining high-aspect ratio micro barrier rip array structure using orthogonal cutting method. It is essential to develop technological methods to solve these problems. The optimum machining conditions for machining micro barrier rip array structures having high-aspect ratio were determined according to lengths ($200{\mu}m$ and $600{\mu}m$) and shape angles ($2.89^{\circ}$ and $0^{\circ}$) of diamond tool, overlapped cutting depths ($5{\mu}m$ and $10{\mu}m$), feed rates (100 mm/s) and three machining processes. Based on the optimum machining conditions, micro barrier rib array structures having aspect ratio 30 was machined in this study.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.5 no.4
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• pp.59-64
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• 2006

High Speed Machining(HSM) reduces machining time and improves surface accuracy because of the high cutting speed and feedrate. Development of HSM makes it allowable to machine difficult-to-cut material and use small-size-endmill. It is however limited to cutting condition and tool material. In the machining operation, it is important to check main parameter of tool life and select optimal cutting condition because tool breakage can interrupt progression of operation. In this study, cutting parameters are determined to 3 factors and 3 levels which are a spindle speed, a feedrate and a width of cut. Experiment is designed to orthogonal array table for L9 with 3 outer array using Taguchi method. Also, it is proposed to inspect significance of the optimal factors and levels by ANOVA using average of SN ratio for tool life. Finally, estimated value of SN ratio in the optimal cutting condition is compared with measured one in the floor shop and reduction of loss is predicted.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.973-976
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• 1997

Process behavior in metal cutting results from the chip formation process which is not easily observable and measurable during machining. By means of the finite element method chip formation in orthogonal metal cutting is modeled. The reciprocal interaction between mechanical and thermal loads is taken into consideration by involving the thermo-viscoplastic flow behavior of workpiece material. Local and temporal distributions of stress and temperature in the cutting zone are calculated depending on the cutting parameters. The calculated cutting forces and temperatures are compared with the experimental results obtarned from orthogonal cutting of steel AISl 4140. The model can be applied in process design for selection of appropriate tool-workpiece combination and optimum cutting conditions in term of mechanical and thermal loads.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.10a
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• pp.365-370
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• 1999

SKD11 is one of the most difficult workpiece for machining, so it is necessary to evaluate the machining characteristics of SKD11. The workpiece was made to be the pipe form and heat-treated to HRC45. In this paper, the orthogonal cutting experiment of this material was carried out with TiAlN coated WC cutting tool of 4 kinds of rake angle. After cutting experiment, cutting characteristics of SKD11 were investigated according to variation of cutting speed, feedrate and rake angle.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.2
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• pp.177-185
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• 2004

The machining performance of wire electrical discharge machining(WEDM), such as cutting speed, surface roughness and straightness depend on the electrode, and the machining parameters are diverse and affect each other. Therefore operator must have a lot of experiences of the parameter for the better machining performance in WEDM. An approach to minimize the time for determining of parameters setting is proposed. Based on the Taguchi method, the significant factors affecting the machining performance are determined. Types of electrodes are arranged at inner array in tables of orthogonal arrays so that we can estimate machining performances of each electrode. Coating wire shows better performances than brass wire in cutting speed but it produces poor surface roughness, and two wires shows similar performance in straightness

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.8
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• pp.81-87
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• 2020

A stable rotational-to-linear motion transformation structure using a driving mechanism with 2 degrees of freedom was developed for an orthogonal mechanism to prevent the interference of each axis in 2D motion. In this mechanism, a step motor was used for precise position control. This structure was developed to maneuver workparts in micro particle blast machining experiments. To determine the real-time performance of micro particle blast machining, the control, input, and output were operated simultaneously and precise position control was implemented, using a timer interrupt with multiple execution codes. The two step motors obtained precise position control by removing backlash with a ball-screw mechanism. The device has menu-type control codes for user-friendliness, and real-time sequence control was simultaneously adopted for user control input.

• Korean Journal of Computational Design and Engineering
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• v.4 no.1
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• pp.43-51
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• 1999

Producing the relevant information (features) from the CAD models of CAM, called feature recognition or extraction, is the essential stage for the integration of CAD and CAM. Most feature recognition methods, however, have problems in the recognition of intersecting features because they do not handle the intersection geometry properly. In this paper, we propose a machining feature recognition algorithm, which has a solid model consisting of orthogonal primitives as input. The algorithm calculates candidate features and constitutes the Intersection Geometry Matrix which is necessary to represent the spatial relation of candidate features. Finally, it recognizes machining features from the proposed candidate features dividing and growing systems using half space and Boolean operation. The algorithm has the following characteristics: Though the geometry of part is complex due to the intersections of design primitives, it can recognize the necessary machining features. In addition, it creates the Maximal Feature Volumes independent of the machining sequences at the feature recognition stage so that it can easily accommodate the change of decision criteria of machining orders.

• Journal of the Semiconductor & Display Technology
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• v.17 no.2
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• pp.61-66
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• 2018

The objective of this research study is to investigate the optimal process parameters of electrical discharge machining (EDM) on SCM440 steel with copper as a tool electrode. The effect of various process parameters on machining performance is investigated in this study. Modern ED machinery is capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, etc. This paper reports the results of an experimental investigation by Taguchi method carried out to study the effects of machining parameters on material surface roughness in electric discharge machining of SCM440 steel. To predict the optimal condition, the experiments are conducted by using Taguchi's L27 orthogonal array. The work material was ED machined with copper electrodes by varying the pulsed current, pulse on-time, voltage, servo speed and spark speed. Investigations indicate that the surface roughness is strongly depend on pulsed current.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.1
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• pp.42-49
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• 2010

In general, the direct experimental approach to study machining processes is expensive and time consuming, especially when a wide range of parameters are included: tool, geometry, materials, cutting conditions, etc. The aim of this study is to verify the effectiveness of finite element method for orthogonal cutting process by comparing the simulated cutting forces with measured results. Two commercialized finite element codes $AdvantEdge^{TM}$ and Deform-$2D^{TM}$ have been used to simulate the cutting forces in orthogonal cutting process. In this paper, estimated cutting and feed force components are compared with experimental results for different two materials. As a result, it has been found that FEM simulation is effective for understanding and predicting the orthogonal cutting process although some improvements on friction model and remeshing process are needed.

• Journal of the Semiconductor & Display Technology
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• v.18 no.2
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• pp.17-22
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• 2019

The method of electrical discharge machining (EDM), one of the processing methods based on non-traditional manufacturing procedures, is gaining increased popularity, since it does not require cutting tools and allows machining involving hard, brittle, thin and complex geometry. This present investigation details the determination of optimum process parameter to attain the better machining performance in EDM of AISI 4340 steel with graphite as a tool electrode. The experimental combinations are planned and analyzed by Taguchi's design of experiments approach. To predict the optimal condition, the experiments are conducted by using Taguchi's L27 orthogonal array. The influence of process variables such as discharge current, pulse on and pulse off time, voltage and spark speed were investigated to control the various desired performance measures such as surface roughness. Analysis of Variance (ANOVA) has to be performed to know the magnitude of each factor. Investigations indicate that the surface roughness is strongly depend on pulsed current.