• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.5
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• pp.1041-1053
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• 1993

A theoretical model to predict the triangular chip formation in cutting with a self-propelled rotary tool is developed. The model is based on the model of transient chip formation in two dimensional orthogonal cutting. The predicted results are found to be in good agreement with the experimental observations and suggest that transient charcteristics of work material, which depend on both cutting conditions and material properties, have the significant influence on triangulation.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.1
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• pp.30-35
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• 2001

Nickel-based heat resisting alloys are commonly used for high temperature application such as in aircraft engines and gas turbines. In this paper, the machinability of Nickel-based heat resisting alloys was investigated with respect to the wear and the chip formation by tool type and cutting condition. Relationship between three types of tool and chip formation was experimentally investigated. Among the three types of tool tested, coated tools(CVD, PVD) ara available for the difficult-to-cut-materials such as Nickel-based heat resisting alloys and etc.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.264-269
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• 2000

Nickel-based heat resisting alloys are commonly used for high temperature applications such as in aircraft engines and gas turbines. In this paper, the machinability of Nickel-based heat resisting alloy was investigated with respect to the wear and the chip formation by tool type and cutting condition. Relationship between three types of tool and chip formation was experimentally investigated. Among the three types of tool tested, coated tools(CVD, PVD) are available for the difficult-to-cut-materials such as Nickel-based heat resisting alloy and etc..

• Journal of the Korean Society for Precision Engineering
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• v.10 no.4
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• pp.206-215
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• 1993

The finite element method is applied to analyze the mechanism of metal cutting, especially micro metal cutting. This paper introduces some effects, such as constitutive deformation laws of workpiece material, friction of tool-chip contact interfaces, tool rake angle and also simulate the cutting process, chip formation and geometry, tool-chip contact, reaction force of tool. Under the usual plane strain assumption, quasi-static analysis were performed with variation of tool-chip interface friction coefficients and tool rake angles. In this analysis, cutting speed, cutting depth set to 8m/sec, 0.02mm, respectively. Some cutting parameters are affected to cutting force, plastic deformation of chip, shear plane angle, chip thickness and tool-chip contact length and reaction forces on tool. Several aspects of the metal cutting process predicted by the finite element analysis provide information about tool shape design and optimal cutting conditions.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.04b
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• pp.300-304
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• 1993

Chip formation control is an important problem in the automation of manufacturing process, since the continuous chip can cause catastrophic failures of the tooling and entangle the workpiece causing damage. However, it is impossible to predict chip form correctly due to the complex nature of cutting process. In order to detect the chip form for unmanned manufacturing, a new identification method is proposed. The feasibility of using acoustic emission signals from the sensing plate for identification of chip form is investigated. Experiments were conducted under the various cutting conditions. When the acoustic emission sensor is attached to the sensing plate, it turns out that the moving averaged AE signals correlated well with the collision of segmented chips with the plate. The sensitivity of moving averaged AE signals to chip congestions due to continuous chip formation is illustrated as well.

• Journal of the Korean Society of Visualization
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• v.18 no.3
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• pp.103-108
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• 2020

RBC (red blood cell) deformability is one of factors inducing blood shear thinning effect. Reduction of RBC deformability increases blood viscosity in high shear region. In this study, 3D printed chip with proper distribution of wall shear rate (WSR) was proposed to measure RBC deformability of blood samples. To fabricate 3D printed chip, the design of 3D printed chip determined through numerical simulation was modified based on the resolution of the 3D printer. For the estimation of pressure drop in the 3D printed chip, two bypass outlets with low and high WSR are exposed to atmospheric pressure through the needles. By positioning the outlet of needles in the gravity direction, the formation of droplets at bypass outlets can be captured by smartphone. Through image processing and fast Fourier transform (FFT) analysis, the frequency of droplet formation was analyzed. Since the frequency of droplet formation is related with the pressure at bypass, high pressure drop caused by reduction of RBC deformability can be estimated by monitoring the formation of blood droplets using the smartphone.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.427-733
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• 2003

Adiabatic shear bands have been observed in the serrated chip during high strain rate metal cutting process of medium carbon steel and titanium alloy. The recent microscopic observations have shown that dynamic recrystallization occurs in the narrow adiabatic shear bands. However the conventional flow stress models such as the Zerilli-Armstrong model and the Johnson-Cook model, in general, do not predict the occurrence of dynamic recrystallization (DRX) in the shear bands and the thermal softening effects accompanied by DRX. In the present study, a strain hardening and thermal softening model is proposed to predict the adiabatic shear localized chip formation. The finite element analysis (FEA) with this proposed flow stress model shows that the temperature of the shear band during cutting process rises above 0.5T$\sub$m/. The simulation shows that temperature rises to initiate dynamic recrystallization, dynamic recrystallization lowers the flow stress, and that adiabatic shear localized band and the serrated chip are formed. FEA is also used to predict and compare chip formations of two flow stress models in orthogonal metal cutting with AISI 1045. The predictions of the FEA agreed well with the experimental measurements.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.155-160
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• 2001

In the use of glass fiber reinforced plastics(GFRP) it is often necessary to cut the components, but the cutting of GFRP is often made difficult by the delamination of the compositions and short tool life. Experimental investigation was conducted to evaluate the chip formation of the glass fiber reinforced plastics during orthogonal cutting. The chip formation process, cutting force, and thrust force were studied. The chip formation processes were studied through the use of quick-stop device. Chip-tool contact areas were obtained with the use of the quick-stop device, and observed using optical microscopy after polishing. Cutting force and thrust force were measured through the use of the tool dynamometer.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.9
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• pp.55-62
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• 2003

This paper investigates the micro-cutting of cemented carbides using PCD (polycrystalline diamond) and PCBN (polycrystalline cubic boron nitride) cutting tools are performed with SEM direct observation method. The purpose of this study is to make clear the cutting mechanism of cemented carbides and the fracture of WC particles at the plastic deformation zone in orthogonal micro-cutting. And also to achieve systematic understanding, the effect of machining parameter on chip formation and machined surface was studied, including cutting speed, depth of cut and various tool rake angle. Summary of the results are shown below. (1) Three type of chip formation process have been proposed by the results of the direct observation in orthogonal micro-cutting of cemented carbide materials. (2) From the whole observation of chip formation, primary WC particles are crushed and/or fine grained in the shearing deformation zone. A part of them are observed to collide directly with a cutting edge of tool by following the micro-cutting. (3) Surface finish, surface morphology and surface integrity is good to obtain by cutting with PCD cutting tool compared with PCBN. (4) The machined surface has the best quality near the low cutting speed of 10${\mu}m$/sec with a cutting depth of 10 ${\mu}m$ using 0$^\circ$ rake angle and 3$^\circ$ flank angle in this condition, but it was found that excessively low speed, for example the extent of 1 ${\mu}m$/sec, is not good enough to select for various reason.

• Journal of the Korean Society for Precision Engineering
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• v.7 no.4
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• pp.73-84
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• 1990

A burr has been defined as an undesirable projection of material formed as the result of plastic flow from a cutting or shearing operation. It is Unavoidable in all kinds of machining operation. This paper describe the burr formation mechanism which is based on the behavior of workpiece material during orthogonal machining of the clay on the milling machine. Specially in this report the rollover burr is dealt as a specific case of the chip formation in the final stage of cutting. The negative shear angle is introduced as an important features of burr formation. It is found that the burr formation process is divided into three stage-initiation, development of negative shearing, and formation of the burr with appropriate assumptions. Using above the burr formation mechanism, the size of burr can be estimated by cutting conditions.