• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.78-82
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• 2001

This paper presents the numerical analysis and experimental verification to know the metal cutting burr formation mechanism in face milling operation. Finite element method are applied to predict the 2-D burr formation process prediction. Face milling process are adjusted to analyze the characteristics of burr shapes according to various cutting conditions. The cutting parameters were investigated with cutting speed, feed rate, depth of cut. Through a few experiments, various burr types are classified according to its shape and properties.

• Advances in materials Research
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• v.11 no.4
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• pp.375-390
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• 2022

Carbon Fiber Reinforced Polymer (CFRP) composite provides outstanding mechanical capabilities and is therefore popular in the automotive and aerospace industries. Drilling is a common final production technique for composite laminates however, drilling high-strength composite laminates is extremely complex and challenging. The delamination of composites during the drilling at the entry and exit of the hole has a severe impact on the results of the holes surface and the material properties. The major goal of this research is to investigate contemporary industry solutions for drilling CFRP composites: enhanced edge geometries of cutting tools. This study examined the occurrence of delamination at the entry and exit of the hole during the drilling. For each of the 80°, 90°, and 118°point angle uncoated Brad point, Dagger, and Twist solid carbide drills, Taguchi design of experiments were undertaken. Cutting parameters included three variable cutting speeds (100-125-150 m/min) and feed rates (0.1-0.2-0.3 mm/rev). Brad point drills induced less delamination than dagger and twist drills, according to the research, and the best cutting parameters were found to be a combination of maximum cutting speed, minimum feed rate, and low drill point angle (V:150 m/min, f: 0.1 mm/rev, θ: 80°). The feed rate was determined to be the most efficient factor in preventing hole entry and exit delamination using analysis of variance (ANOVA). Regression analysis was used to create first-degree mathematical models for each cutting tool's entrance and exit delamination components. The results of optimization, mathematical modelling, and experimental tests are thought to be reasonably coherent based on the information obtained.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.4
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• pp.397-402
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• 2013

In this study, we carried out the each lines of section, using GC (green silicon carbide) whetstone, the SCM415 material which separated by after and before heat treatments process, in 3+2 axis machining centers for integrated grinding after cutting end mill works, the spindle speed 8000 rpm and feed rate 150 mm/min. For the analysis of the centerline average roughness (Ra), we measured by 10 steps stages. Using Finite element analysis, we found the result of the load analysis effect of the assembly parts, when applied the 11 kg's load on both side of the ATC (Automatic tool change) arm. The result is as follows. For the centerline average roughness (Ra) in the non-heat treatment work pieces, are appeared the most favorable in the tenth section are $0.510{\mu}m$, that were shown in the near the straight line section which is the smallest deformation of curve. In addition, the bad surface roughness appears on the path is to long by changing angle, the more inclined depth of cut, because the chip discharging is not smoothly.

• Steel and Composite Structures
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• v.34 no.5
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• pp.681-698
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• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.

• Journal of Ocean Engineering and Technology
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• v.36 no.3
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• pp.143-152
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• 2022

To reach a port, a ship must pass through a shallow water zone where seabed effects alter the hydrodynamics acting on the ship. This study examined the maneuvering characteristics of an autonomous surface ship at 3-DOF (Degree of freedom) motion in deep water and shallow water based on the in-port speed of 1.54 m/s. The CFD (Computational fluid dynamics) method was used as a specialized tool in naval hydrodynamics based on the RANS (Reynolds-averaged Navier-Stoke) solver for maneuvering prediction. A virtual captive model test in CFD with various constrained motions, such as static drift, circular motion, and combined circular motion with drift, was performed to determine the hydrodynamic forces and moments of the ship. In addition, a model test was performed in a square tank for a static drift test in deep water to verify the accuracy of the CFD method by comparing the hydrodynamic forces and moments. The results showed changes in hydrodynamic forces and moments in deep and shallow water, with the latter increasing dramatically in very shallow water. The velocity fields demonstrated an increasing change in velocity as water became shallower. The least-squares method was applied to obtain the hydrodynamic coefficients by distinguishing a linear and non-linear model of the hydrodynamic force models. The course stability, maneuverability, and collision avoidance ability were evaluated from the estimated hydrodynamic coefficients. The hydrodynamic characteristics showed that the course stability improved in extremely shallow water. The maneuverability was satisfied with IMO (2002) except for extremely shallow water, and collision avoidance ability was a good performance in deep and shallow water.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.6
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• pp.1121-1140
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• 1992

In metal cutting the shape of generated chip varies according to cutting conditions, characteristics of workpiece and geometry of cutting tool. The best surface roughness of machined workpiece is obtained when generating flow type contrinuous chip. If the generated chip is not broken, that is not only tangled workpiece and cutting tool, but also may give damage on the machined surface of workpiece or danger for a operator. The flow type continuous chip may bring the low productivity in high speed any heavy cutting, automatic machining process and non-human factory. There are two type of chip break process ; controlling cutting condition and using chip breaker. In present study we carried out the experiment on new type chip breaker compared with conventional type and proved the efficiency of a new type and showed the chip break condition to be applied in actual metal cutting. In the experiment SM 20 C as a workpiece material and WC as a tool material were used and cutting speed of 30-150m/min, feed of 0.071-0.210mm/rev and depth of cut of 1mm were applied as cutting condition. The results of the experiment are as follows : (1) The mechanism of chip curl can be explained more clearly by plastic flow of workpiece material and moment of shearing force. (2) The most effective radius of curled chip and flat distance from cutting edge is 2.0-2.5mm and 1.5mm in both types. (3) The effective inclination angle of chip break surface and side cutting edge angle are 30.deg.- 45.deg. and 20.deg. in conventional type, while the radius of arc surface, lower arc angle A, upper arc angle B and side cutting edge angle are 3mm, 20.deg.- 45.deg., 0.deg.- 45.deg. and 10.deg.- 20.deg. in new type. (4) The probability to be obtained 100% chip breaking ratio is much higher in new type than in conventional type.

• Journal of the Korean Society of Safety
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• v.24 no.2
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• pp.7-12
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• 2009

The machining process of ceramics can be characterized by cracking and brittle fracture. In the machining of ceramics, edge chipping and crack propagation are the principal reasons to cause surface integrity deterioration. Such phenomenon can cause not only poor dimensional and geometric accuracy, but also possible failure of the ceramic parts. Thus, traditional ceramics are very difficult-to-cut materials. Generally, ceramics are machined using conventional method such as grinding and polishing. However these processes are generally costly and have low MRR(material removal rate). To overcome such problems, in this paper, h-BN powder, which gives good cutting property, is added for the fabrication of machinable ceramics by volume of 10 and 15%. The purpose of this study is an analysis of endmill's rake angle for appropriate tools design and manufacturing for the machinable ceramics. In this study, Experimental works are executed to measure cutting force, surface roughness, tool fracture, on different axial rake angle of endmills. Cutting parameters, namely, feed, cutting speed and depth of cut are used to accomplish purpose of this paper. Required experiments are performed, and the results are investigated.

• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.1-13
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• 2016

The increase of consumer needs for quality metal cutting related products with more precise tolerances and better product surface roughness has driven the metal cutting industry to continuously improve quality control of metal cutting processes. In this paper, two different approaches are discussed. First, design of experiments (DOE) is used to determine the significant factors and then fuzzy logic approach is presented for the prediction of surface roughness. The data used for the training and checking the fuzzy logic performance is derived from the experiments conducted on a CNC milling machine. In order to obtain better surface roughness, the proper sets of cutting parameters are determined before the process takes place. The factors considered for DOE in the experiment were the depth of cut, feed rate per tooth, cutting speed, tool nose radius, the use of cutting fluid and the three components of the cutting force. Finally the significant factors were used as input factors for fuzzy logic mechanism and surface roughness is predicted with empirical formula developed. Test results show good agreement between the actual process output and the predicted surface roughness.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.1
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• pp.106-113
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• 2010

The most suitable condition for plasma source ion implantation(PSII) was found based on the study of the characteristics of PSIIed tool and machined surfaces. The depth analysis according to the chemical bonding state of elements and surface component elements through the XPS and SIMS, was conducted to find the improved property of the PSIIed surface. Due to the diffusion of PSII, the nitrogen was found up to a depth of about 150nm according to the supplied voltage and ion implanted time. The deep diffusion by nitrogen caused the surface modification, but the formation of oxide component was found due to the residual gas contamination on the surface. Statistical method of ANOVA was conducted to find the effects of spindle speed and feed rate in interaction for machined surface roughness with PSIIed tools. The surface modification was found largely occurred by the nitrogen implanted surface with 2 hours for 27kV, 35kV and 43kV.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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• pp.123-129
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• 2022

Quartz (SiO2) has high abrasion and heat resistances and excellent chemical and mechanical properties; therefore, it is used in various industries, such as machinery, chemistry, optics, and medicine. Quartz is a high-hardness and brittle material and is classified as the topmost difficult-to-cut material, which is because of the cracking or chipping at the edge during processing. Corner wear, such as cracks and chippings that occur during cutting, is a major cause for the deterioration in the machining quality. Therefore, many researchers are investigating various techniques to process quartz effectively. However, owing to the mechanical properties of quartz, most studies have been conducted on grinding, micromachining, and microdrilling. Few studies have been conducted on quartz processing. The purpose of this study was to analyze the machining characteristics according to the machining factors during the slot machining of quartz using a cubic boron nitride (CBN) tool and to select the optimal machining conditions using the Taguchi method. The machining experiment was performed considering three process variables: the spindle speed, feed rate, and depth of cut. The cutting force and surface roughness were analyzed according to the processing conditions.