• KSTLE International Journal
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• 제3권1호
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• pp.17-22
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• 2002

Roughing of tool steel in its hardened state represents a real challenge in the die and meld industry and process improvement depends on research of tool material, coating technique, and lubrication. However, roughing of hardened steels generates extreme heat and without coolant flooding, tool material cannot withstand the high temperature without choosing the right tools with proper coating. This research conducted milling tests using coated ball end mills to study effects of cutting conditions and geometric parameters of ball end mills on the machinability of hardened tool steel. KP4 steel and STD 11 heat treated steels were used in the dry cutting as the workpiece and TiAIN coated ball end mills with side relief angle of 12$^{\circ}$ was utilized in the cutting tests. Cutting forces, tool wear, and surface roughness were measured in the cutting tests. Results from the experiments showed that 85 m/min of cutting speed and 0.32 mm/rev of feed rate were optimum conditions for better surface finish during rough cutting and 0.26mm/rev with the same cutting speed are optimum conditions in the finish cutting.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 한국소성가공학회 2004년도 제5회 압연심포지엄 신 시장 개척을 위한 압연기술
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• pp.368-377
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• 2004

A mathematical model was developed for the prediction of the average temperature and RDT(RM Delivery temperature) in a roughing mill. The model consisted of three parts as follows (1) The intermediate numerical model calculated the deformation and heat transfer phenomena in the rolling: region by steady state FEM and the heat transfer phenomena in the interpass region by unsteady state FEM (2) The Off-line prediction model was derived from non-linear regression analysis based on the results of intermediate numerical model considering the various rolling conditions, (3) Using the heat flux in rolling region, temperature profile along thickness direction was calculated. For validation of the presented model, the rolling force per pass and RDT measued in on-line process was compared with those of model and the results showed close agreement with the existing data. In order to demonstrate the effectiveness of the proposed model, the various rolling conditions was tested.

• Transactions of Materials Processing
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• 제9권1호
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• pp.66-71
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• 2000

The present study tackles the metallurgical subjects involving the thin slab-direct hot rolling process, i.e. mini-mill process. In order to clarify the effect of chemical composition of steel and MnS precipitation behaviors on the development of edge cracking during hot rolling, the content of manganese and sulfur in low carbon steel was varied and the isothermal treatment prior to roughing was applied. Edge cracking during roughing in the hot-rolling process of mini-mill was effectively prevented by means of the isothermal treatment at 115$0^{\circ}C$ for 5 minutes in the 0.4% manganese steel containing sulfur lower than 0.013%. With the increase in manganese content in low carbon steel, coarser MnS developed. The edge cracking index which denotes the total length of edge crack per unit edge-length of rolled specimens was proposed in this paper. It was found that the edge cracking index linearly decreased with the increase in the ratio of MnS.

• Journal of the Korean Society of Manufacturing Process Engineers
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• 제18권11호
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• pp.89-95
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• 2019

In this research, the effect of roughing on tool load through bottom-up machining is investigated through actual machining. Generally, through the use of high-speed machining technology, machining methods, such as general roughing, operate by deepening the cutting depth for as long as the tool is able to withstand it, giving a slower feed rate, less cutting depth, and faster feed. However, when the cutting depth is deep, there is a problem in that the stepped shape of the cutting area is increased (e.g., by the shaking of the tool or the chipping load). However, if the cutting is performed less, the cutting time becomes relatively long. To compensate for these drawbacks and extend the service life of the tool, economic efficiency needs to be secured.

• Transactions of the Korean Society of Automotive Engineers
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• 제24권1호
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• pp.67-73
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• 2016

The application of titanium has been gradually rising because the utilizing ranges for low weight and high strength are rapidly increased by the need for improving the fuel economy in production industries such as the aviation and automotive in recent. The purpose in this study is to investigate the appropriate cutting conditions on the life of flat and round end mills by measuring the maximum cutting temperature relative to the machining time, and calculating the wear rates of cutting tool with the spindle speed and feed rate of vertical machining center as a parameter in the titanium roughing cut machining which is widely used in critical parts of aircraft, cars, etc. When the wetted roughing cut machining of titanium with a soluble cutting oil is conducted by the flat and round end mills, the maximum cutting temperatures for a variety of spindle speed and feed rate are measured at ten-minute intervals during 60 minutes by an infrared thermometer, and the wear rates of cutting tool are calculated by the weight ratios based on tool wear before and after the experiment. It is found that the maximum cutting temperature and the wear rates of cutting tool are raised as the cutting amount per tool edge is increased with the rise of feed rate, in this experimental range, and as the frictional area due to the rise of contacting friction numbers between tool and specimen is increased with the rises of cutting time and spindle speed. In addition, the increasing rate of maximum cutting temperature in the flat and round end mills are the highest for the cutting time from 50 to 60 minutes, and the wear rate of cutting tool in the flat end mill is 1.14 to 1.55 times higher than that in the round end mill for all experimental conditions.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 한국정밀공학회 2007년도 추계학술대회 논문집
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• pp.217-218
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• 2007

• Journal of the Korean Society of Manufacturing Process Engineers
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• 제15권1호
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• pp.34-41
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• 2016

Bar camber is a phenomenon in which a material with a deformation gradient across its width is bent in the right or left direction in the roll gap. This paper proposes a dynamic setup approach for a side guide for reducing bar camber. A bar tracking scheme using a rotary encoder was adopted to fix an operation point for the side guide. The guiding pressure was utilized for measuring the actual width of the bar with camber. Based on the accurate position and width of the bar, the side guide was dynamically set and operated at the actual roughing train in a hot strip rolling mill. The amount of camber was reduced notably when the dynamic setup scheme was installed in the side guide. 78% of the bars tested had a camber in the range of ${\pm}20mm$, which was an improvement of 27% in terms of production yield.

• Transactions of the Korean Society of Machine Tool Engineers
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• 제15권5호
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• pp.79-84
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• 2006

In modem manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are designed and produced. In the production of these complex-shaped mechanical components, e.g. automobile dies, molds, and various engineering applications, the ball-end milling process is one of the most widely used NC machining processes that consists of roughing, semi-finishing and finishing. In semi-finishing, cusps remained after roughing according to the used tools that have two patterns of stairs and wave shapes. These cusp shapes have air-cut in cutting and instability caused by high cutting speed that affects the cutting characteristics such as cutting force and tool wear. Cutting characteristics are measured and analyzed through cutting force, FFT analysis of cutting force and tool wear along cutting length according to low tool paths with same metal removal rate. As a results of the experiments, this study suggests the optimal conditions of tool path and cutting direction. This approach for the cutting characteristics of semi-finishing provides a useful aid for the productivity and efficiency improvements of NC machining processes.

• Journal of Korean Society of Water and Wastewater
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• 제32권4호
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• pp.301-307
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• 2018

Membrane distillation (MD) is a thermally driven desalination process with a hydrophobic membrane. MD process has been known to have a lower fouling potential compared to other pressure-based membrane desalination process (NF, RO). However, membrane fouling also occurs in MD process. In this study, the membrane fouling was observed in MD process according to the pre-treatment processes. The filtration and precipitation processes were applied as the pre-treatment to prevent the membrane fouling. The pore sizes of roughing filters were 0.4, 5, 10, 30, and $60{\mu}m$. The concentration of the coagulant was 1.2 mg/L as $FeCl_3$. The membrane fouling on MD membrane was successfully removed with both pre-treatment processes.

• Journal of Institute of Control, Robotics and Systems
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• 제16권10호
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• pp.1006-1012
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• 2010

The hot rolling process ranks the highest position for production in steel making process. The hot strip manufacturing processes consist of the reheating furnace, roughing and finishing mill and coiler. The reheating furnace heats the slab. The roughing and finishing mill produce the hot strip from slab. The hot strip quality mainly depends on finishing mill, which consists of 4-high 7 stands. The looper is installed between stands and is used for controlling the strip tension by the looper angle for better material flow. It is difficult to control the strip tension with the coupled looper system from interaction between the looper angle and strip tension. Too much deviation of strip tension severely affects the poor width quality of the hot strip. It is important to control simultaneously both the looper angle and strip tension with each of their target values. This paper proposes the fuzzy tension control, which is developed to minimize the width deviation of the hot strip by maintaining the proper strip tension between stands and to achieve the stable operation of the coupled looper system. The fuzzy tension control performance is compared with the conventional PID control by experimental results.