• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.4 no.3
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• pp.12-24
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• 1995

Various surface grinding experiments using resin bonded diamond abrasive wheels are carried out for tungsten carbide materials in order to minimize the damage on the ground surface and to purse the precise dimension compared to conventional grinding machine. When grinding quality is constant, theoretical grinding effect is changed according to the speed of workpiece. Accordingly, grinding forces, which are Fn, Ft, were analyzed for the machining processes of tungsten-carbide material to obtain optimum grinding conditions. Brief investigation is carried out to decrease the dressing efficiency of resinoid bonded diamond grinding wheel to grind tungsten-carbide. Truing is also carried out to provide a desired shape on a wheel or to correct a dulled profile. High quality in dimensional accuracy and surface are often required as a structural components, therefore 3-points bending test is carried out to check machining damage on the ground surface layer, which in one of sintered brittle material. From this experimental study, some useful machining data and information to determine proper machining condition for grinding of tungsten-carbide materials are obtained.

• Korean Journal of Computational Design and Engineering
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• v.4 no.3
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• pp.247-258
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• 1999

With the contemporary CAD/CAM system, where the tool path is generated and verified purely based on the geometric operation, geometric accuracy of the machined surface cannot be guaranteed dut to the cutting mechanics, meaning that the cutting mechanics should be incorporated in some fashion. In this paper, we incorporate the instantaneous cutting force and the tool deflection phenomena in predicting the machined surface for the finish-cut and milling operation. For the given NC dat including cutting conditions, the developed algorithm computes cutting force and deflection amount along the tool trajectory, and outputs the 3D graphic model of the machined surface together with error analysis. The validity and accuracy of the presented method has been tested by the actual cutting experiments. Experimental results and accuracy enhancement method together with implementing architecture of the VMCS (Virtual Machining CAM System) are discussed in the paper.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.3
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• pp.17-23
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• 2004

The performance and life of a die are influenced by the machining methods. In order to examine the effects of machining methods on surface charactenstics, simple experiments are devised and performed. A die steel STD11, commonly used as a die material in press working, is selected. Three ways of machining methods to manufacture a die are considered. Those are (1) milling and then grinding, (2) wire-cut electric discharge dachining (W-EDM) and (3) heat treatment after W-EDM. The resulting surface roughnesses are measured. Also, the changes of surface microstructures are investigated using the scanning electron microscope(SEM) with energy dispersive X-ray spectrometer(EDS) and the results are discussed in details.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.12
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• pp.191-197
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• 2003

As mechanical components are miniaturized, the demand on micro die and mold is increasing. Micro mechanical components usually have high hardness and good conductivity. So micro electrical discharge machining (MEDM) is an effective way to machine those components. In micro cavity fabrication using MEDM, it is observed that the bottom surface of cavity is distorted. Electric charges tend to be concentrated at the sharp edge. At the center of the bottom surface, debris can not be drawn off easily. These two phenomena make the bottom surface of the electrode and workpiece distort. As machining depth increases, the distorted shape of electrode approaches hemisphere. This process is affected by capacitance and the size of electrode. By using a smaller electrode than the desired cavity size and appropriate tool movement, bottom shape distortion can be prevented.

• International Journal of Precision Engineering and Manufacturing
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• v.6 no.4
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• pp.44-48
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• 2005

As mechanical components are miniaturized, the demands on micro die/mold are increasing. Micro mechanical components usually have high hardness and good conductivity. Micro electrical discharge machining (MEDM) can thus be an effective way to machine those components. In micro cavity fabrication using MEDM, it is observed that the bottom surface of the cavity is distorted. Electric charges tend to be concentrated at the sharp edge, and debris cannot be drawn off easily at the center of the bottom surface. These two phenomena make the bottom surface of electrode and workpiece distort. As machining depth increases, the distorted shape of the electrode approaches hemisphere. This process is affected by both capacitance and the size of electrode. By using a smaller electrode than the desired cavity size and appropriate tool movement, bottom shape distortion can be prevented.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.589-592
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• 2003

In the machining process of micros shape by using high-precision machining system and micro end-mill, it is important for machining characters of tools to be grasped in order to stably use tools of micro end-mill. In this study. we carried out an analytical experiment of basic machining features by using end-mill tools for the purpose of damage prevention and manufacture of high quality when the tools of micro end-mill are used. This experiment used a micro machining system with high precision and a variety of end-mill tools commercialized from tens to hundreds microns in diameter. To establish an optimal machining condition without tool damage, cutting force was analyzed according to the changes of tool diameter and cutting conditions such as cutting speed. feed rate, depth of cut. And an examination was performed for the shape and surface illumination of machining surface according to the changes of machining conditions. Based on these micro machining conditions, micro square pillar, cylinder shaft. thin wall with high aspect ratio, and micro 3-D structures such as micro gear and fan were manufactured.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.5
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• pp.543-547
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• 2011

Primary water stress corrosion cracking has occurred in dissimilar weld areas in nuclear power plants. Residual stress is a driving force in the crack. Residual stress may be generated by weld or surface machining. Residual stress due to surface machining depends on the machining method, e.g., milling, grinding, or EDM. The stress is usually distributed on or near the surface of the material. We present the measured residual stress for machining on SA 508 and austenitic stainless steels such as TP304 and F316. The residual stress can be tensile or compressive depending on the machining method. The depth and the magnitude of the residual stress depend on the material and the machining method.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.1
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• pp.49-55
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• 2015

Recently, many researchers and industry are looking for ways to decrease the use of lubricants because of economical and environmental reasons. One of the lubrication technologies is the MQL method. This study presents a research of MQL and Wet milling processes of Al 6061 material. For this experiment, the test specimen is suggested, and various machining conditions are applied. And, shape of micro-pattern which has been recently spotlighted is included in the test specimen. In order to compare MQL with Wet machining, several milling experiments were carried out, varying feed rate, cutting speed, depth of cut, etc. Finally, the surface roughness results of machining tests according to the process conditions were measured. It is expected that the results of machining experiments can be used to predict the surface roughness of various MQL milling processes.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.6
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• pp.30-36
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• 2013

An FFD(flexible fine die) is an embossed mold that consists of a thin plate ranging from 0.6 to 3 mm in thickness. FFDs are primarily used for cutting LCD films and F-PCB sheets. In the high-speed micro-milling process of flexible fine dies, the lubrication and cooling of the cutting edges is very important from the aspect of eco machining and cutting performance. In this paper, a comparative study of tool wear and surface roughness between cutting fluid and hybrid lubrication for eco-machining of FFD was conducted for processes of high-speed machining of highly hardened material (STC5, HRC52). Especially, the incorporated fluid method for eco machining, in which the cutting performances can be simultaneously measured, was introduced. The machining results show that hybrid lubrication, instead of conventional cutting fluid, leads to excellent tool wear and surface roughness and represents the proper conditions for eco micro-machining of flexible fine dies.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1844-1847
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• 2003

Electrochemical micro-machining(EMM) is used to achieve a desired workpiece surface by dissolving the metal workpiece with an electrochemical reaction. This machining method can be applied to metal that is difficult to machining using other methods. The workpiece dissolves when it is positioned close to the tool electrode in electrolyte and current is applied. This aim of this work is to develop electrochemical micro-machining(EMM) technique for micro groove shape by establishing appropriate electrochemical parameters of machining