• Journal of the Korean Society for Precision Engineering
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• v.12 no.10
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• pp.121-129
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• 1995

The objective of this research is to develop an effective inspection planning strategy for sculptured surfaces by using 3-dimensional Coordinate Measuring Machine (CMM). First, the CAD/CAM database is generated by using the Bezier surface patch mathod and variable cutter step size approach for design and machining of the workpiece model. Then, optimum measuring point locations are determained based on the mean curvature analysis to obtain more effective inspection results for the given sample numbers. An optimal probe sequence generation method is proposed by implementing the Traveling Salesperson (TSP) algorithm and new guide point selection methods are suggested based on the concepts of the variable distance between the first and second guide points. Finally, simulation study and experimental work show the effectiveness of the proposed strategy.

• Korean Journal of Computational Design and Engineering
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• v.6 no.2
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• pp.69-77
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• 2001

This paper describes a method of calculating the feedrate for the constant cutting speed at a CL-point in 5-axis machining. Unlike 3-axis machining, 5-axis machining has the flexibility of the tool motions due to two rotation axes. But the feedrate at joint space differs from the feedrate at a tool tip(the CL-point) of the 3D Euclidean space for the tool motions. The proposed algorithm adjusts the feedrate based on 5-axis NC data, the kinematics of a machine, and the tool length. The following calculations is processed for each NC block to generate the new feedrate; 1) calculating the moving distance at the CL-point, 2) calculating the moving time by the given feedrate, 3) calculating the feedrate of each axis, 4) getting the new feedrate. The proposed algorithm was applied to a 5-axis machine which had a tilting spindle and a rotary table. Totally, the result of the algorithm reduced the machining time and smoothed the cutting-load by the constant cutting speed at the CL-point.

• Journal of Computational Design and Engineering
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• v.2 no.4
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• pp.233-247
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• 2015

In this paper, the cutting force calculation of ball-end mill processing was modeled mathematically. All derivations of cutting forces were directly based on the tangential, radial, and axial cutting force components. In the developed mathematical model of cutting forces, the relationship of average cutting force and the feed per flute was characterized as a linear function. The cutting force coefficient model was formulated by a function of average cutting force and other parameters such as cutter geometry, cutting conditions, and so on. An experimental method was proposed based on the stable milling condition to estimate the cutting force coefficients for ball-end mill. This method could be applied for each pair of tool and workpiece. The developed cutting force model has been successfully verified experimentally with very promising results.

• Korean Journal of Computational Design and Engineering
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• v.8 no.2
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• pp.115-121
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• 2003

A new Layered Manufacturing(LM) system, named PaperMill, is developed applying micro milling technology. A micro endmill(127 11m in diameter) is introduced as the cutter of build material. The selected build material for this system is an adhesive-coated paper roll which provides advantages such as good bonding between layers, machinability, and low material cost. A 3-axis CNC controller and three step-motors are used for the movement of X-Y-Z table of the system. For simplicity of the control of mechanism, the control system for feeding the paper roll is uncoupled from CNC controller. Two code converters are developed for the toolpath generation of the new LM system. The NC converter generates a set of NC codes for PaperMill using commercial CAM software while the SML converter generates an NC code from Quickslice's SML format. The NC codes generated from the converters consist of a series of profile data and trigger code for paper feeding. Two sample gears were fabricated to prove the concept of the system, which shown that the dimensional errors of the fabricated gears is under 3.4 percent.

• Korean Journal of Computational Design and Engineering
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• v.14 no.5
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• pp.291-296
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• 2009

This paper presents a post-processing algorithm for 5-axis machines with three rotary axes (3R-2L type). 5-axis machining needs the postprocessor for converting cutter location (CL) data to machine control (NC) data. The existing methods for post-processing use inverse kinematics equations from for-ward kinematics. However in case of 5-axis machines with three rotary axes, the inverse kinematics equations are not induced directly since the forward kinematics equations are non-linear. In order to get the joint values from the forward kinematics equations, previous algorithms use numerical method for the post-processing, which needs searching algorithms with computation time and may result in fail. This paper proposes a geometric method for the post-processing of 3 rotary type 5-axis machines. Our algorithm has three advantages: first, it does not need establishing forward kinematics equations. Second, it is reliable method that eliminates any numerical methods for the inverse kinematics, resulting in the exact solution. Finally, the proposed algorithm can also be applied to 2R-3L type of 5-axis machines.

• Journal of Biosystems Engineering
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• v.25 no.3
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• pp.203-212
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• 2000

One of the obstructing factors against managing large-scaled dairy farm in Korea has been heavy labor requirement for feeding dairy cows. A tractor attached TMR mixer was developed to reduce the cost and to provide economic benefit in this research. The TMR mixer was designed to have a feeding capacity of 35 heads at a batch with various functioning systems of paddle type mixer, cutter and grinder, delivery conveyor, weighing console, power transmission train, and mounting trailer. The maximum power required during the mixing operarion was 26.3 kw(P.T.O), readily available from 32kw-rated tractors, which had been widely used in Korea. Low coefficient of variation(14.0%) revealed an uniform mixing performance of the mixer. The mixer can also be used in compost mixing as well as concentrates and roughage.

• Tunnel and Underground Space
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• v.23 no.5
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• pp.428-441
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• 2013

Nowadays, a roadheader as a mechanical excavator is in high demand, especially for mines under various conditions and tunnels where TBMs are inapplicable. However, the records of roadheaders in Korea are seldom reported. Moreover, the number of countries with their intrinsic design and manufacturing technologies of roadheaders is very limited. Therefore, this study aimed to analyse the excavation principles of roadheader as well as its key design parameters for its optimized selection and design. In addition, the database with 143 world-widely collected roadheader design data was built, and a few statistical correlations were derived from it. A schematic procedure for roadheader design based on the database was also proposed.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.8
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• pp.46-59
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• 1998

This paper presents shape design, surface construction, and cutting path generation for the surface of marine ship propeller blades. A propeller blade should be designed to satisfy performance constraints that include operational speed which impacts rotations per minutes, stresses related to deliverable horst power, and the major length of the marine ship which impacts the blade size and shape characteristics. Primary decision variables that affect efficiency in the design of a marine ship propeller blade are the blade diameter and the expanded area ratio. The blade design resulting from these performance constraints typically consists of sculptured surfaces requiring four or five axis contoured machining. In this approach a standard blade geometry description consisting of blade sections with offset nominal points recorded in an offset table is used. From this table the composite Bezier surface geometry of the blade is created. The control vertices of the Hazier surface patches are determined using a chord length fitting procedure from tile offset table data. Cutter contact points and path intervals are calculated to minimize travel distance and production time while maintaining a cusp height within tolerance limits. Long path intervals typically generate short tool paths at the expense of increased however cusp height. Likewise, a minimal tool path results in a shorter production time. Cutting errors including gouging and under-cut, which are common errors in machining sculptured surfaces, are also identified for both convex and concave surfaces. Propeller blade geometry is conducive to gouging. The result is a minimal error free cutting path for machining propeller blades for marine ships.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.5
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• pp.1126-1133
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• 1994

When designing an internal gear. the bending strength around pitch point as well as that at tooth root fillet should be considered because the bending stress around pitch point may occur as high as that at tooth root fillet. In this study, including stress state around pitch point, the bending strength (tensile side and compressive side) of internal gear tooth is investigated by the use of the finite element method(FEM) with regarding many influencing factors of cutter and gear geometries. Then, the critical sections around pitch point and at tooth root fillet are determined, and the simple formulae based on nominal stresses(bending, compressive, and shear) are derived for the calculations of actual stresses as the functions of tooth thicknesses and radii of curvatures of involute and fillet curve at those critical sections. The stresses calculated by the formulae agree well with those by the FEM. And the bending stresses around pitch point and at tooth root are easily estimated by the use of those formulae, therefore, those formulae are useful for the purpose of the design or the bending strength estimation of internal gear.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.2 s.95
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• pp.234-243
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• 1999

Using the geometric and the vector methods, three dimensional surface texture and roughness models in flat end milling are developed. In these models, rear cutting effect on surface generation is considered along with tool run-out and tool setting error including tool tilting and eccentricity between tool center and spindle rotational center. Rear cutting is the secondary cutting of the already machined surface by the trailing cutting edge. The effects of tool geometry and tool deflection on surface roughness are also considered. For representing the surface texture more practically, three dimentional surface topography parameters such as RMS deviaiton, skewness and kurtosis are introduced and used in expressing the surface texture characteristics. Under various cutting conditions, it is confirmed that the developed models predict the real surface profile precisely. These models could contribute to the cutter design and cutting condition selection for the reduction of machining and manual finishing time.