• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.17 no.4
• /
• pp.1-8
• /
• 2018

In drilling Inconel 601, which is used for compressor cases in aircraft engines, a lot of cutting oil must be supplied. This prevents tools from wear and fracture due to the heat buildup resulting from the high-temperature resistance and toughness of this alloy. However, the cutting oil supply has compromised the machining environment. This has caused attention to shift to an environmentally friendly cutting fluid supply system called the Minimum Quantity Lubrication(MQL) system. The aim of this study was to find a more efficient drill processing method using MQL and to verify its performance. To that end, the properties of Inconel that make it difficult -to -drill were studied by a comparison with the drilling of SM45C. Specific factors (i.e., cutting force and tool wear) were examined in relation to the conditions in the MQL-based drilling system. Based on these results, a sealed cover and step feed were proposed as measures to increase the effectiveness of the MQL system. The efficiency of the proposed method was established.

• Journal of the Korean Society for Geothermal and Hydrothermal Energy
• /
• v.17 no.1
• /
• pp.14-22
• /
• 2021

Drilling equipment is an essential part used in various fields such as construction, mining, etc., and it has drawn increasing attention in recent years. The drilling method is generally divided into three types. There are a top hammer method that strikes on the ground, a DTH (Down-The-Hole) method that directly strikes a bit in an underground area, and a rotary method that drills by using rotational force. Among them, the DTH method is most commonly used because it enables efficient drilling compared to other drilling methods. In the conventional DTH hammer, the valve between the piston and the bit is opened and closed using a face to face method. In order to improve the power of the DTH hammer, a DTH hammer with foot valve which is capable of instantaneous opening and closing is used in the drilling field. In this study, we designed a lab-scale DTH hammer with the foot valve, and manufactured an evaluation device for the experiment of the DTH hammer. In addition, we analyzed the performance of the DTH hammer adopted with foot valve according to the pressure range of 3-10 bar. As a result, the internal pressure distribution in the DTH hammer was experimentally analyzed, and then, the movement of the piston according to the pressure was predicted. We believe that this study provides the useful results to explain the performance characteristics of the DTH hammer with the foot valve.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
• /
• 1998.10a
• /
• pp.343-349
• /
• 1998

A modeling of machined geometry and cutting force was proposed for the case of round shape machining, and the effects of internally machined profile are analyzed and its realiability was verified by the experiments of roundness tester, especially in boring operation in lathe. Also, harmonic cutting force model was proposed with the parameter of specific cutting force, chip width and chip thickness, and in this study, we can see that bored workpiece profile was also mapped into cutting force signal with this model. In general, we can calculated the theoretical lobe profile with arbitrary multilobe. But in real experiments, the most frequently measured numbers are 3 and 5 lobe profile in experiments. With this results, we can predict that these results may be applied to round shape machining such as drilling, boring, ball screw and internal grinding operation with the same method.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.16 no.1
• /
• pp.36-41
• /
• 2017

In this paper, $Si_3N_4/hBN$ ceramics with various hexagonal boron nitride (hBN) contents (0, 10, 20, or 30 wt%) were fabricated via spark plasma sintering (SPS) at $1500^{\circ}C$, 50MPa, and 10m holding time. The material properties such as the relative density, hardness, and fracture toughness were systematically evaluated according to the hBN content in the $Si_3N_4/hBN$ ceramics. The results show that relative density, hardness, and fracture toughness continuously decreased as the hBN content increased. In addition, peak-step drilling (with tool diameter $500{\mu}m$) was performed to observe the effects of hBN content in micro-hole shape and cutting force. A machined hole diameter of $510{\mu}m$ (entrance) and stable cutting force were obtained at 30 wt% hBN content. Consequently, $Si_3N_4/30wt%$ hBN ceramic is a feasible material upon which to apply semi-conductor components, and this study is very meaningful for determining correlations between material properties and machining performance.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.12 no.2
• /
• pp.75-80
• /
• 2013

Cathode is an essential component used in plasma etching process which is to make micro pattern on the silicon wafer. The currently used cathodes produce particles at the high temperature plasma etching process. To overcome this problem, a 'Silicon Only Cathode' was developed. This 'Silicon Only Cathode' requires manufacturing process changes due to the change of shapes, material features, and machining characteristics of work materials. This research investigates the small hole drilling process. The conclusion is that PCD drills with twist angles of $20^{\circ}$ and $25^{\circ}$ were tested for small hole drilling and the experimental results indicate that the drill with $25^{\circ}$ twist angle drill causes less thrust force.

• Journal of the Ergonomics Society of Korea
• /
• v.19 no.2
• /
• pp.75-86
• /
• 2000

In this study, the characteristics of transmitted vibration on HAS(hand-arm system) were identified to evaluate physical load due to the work surface orientation, tool weight and push force during powered drilling tasks. The characteristics of transmitted vibration on work surface orientation showed that the acceleration of transmitted vibration on horizontal work surface was higher than that on the vertical work surface. Regarding the characteristics of transmitted vibration on tool weight, the vibration acceleration level becomes lower as the tool weight becomes heavier. The amount of transmitted vibration on hand-arm system was decreased down to the tool weight of 2.4kg. However, as the tool weight becomes heavier than 2.8kg, the amount of transmitted vibration was increased and had peak value at 3.2kg of tool weight. Regarding the characteristics of transmitted vibration on push force, the vibration acceleration level goes higher, as the push force becomes larger. The characteristics of transmitted vibration on the axis of vibration showed that the direction of $Z_h$ had the highest acceleration compared to the direction of $X_h$, and $Y_h$. The direction of $X_h$, $Y_h$ and $Z_h$ had the highest acceleration of transmitted vibration on the hand, wrist and elbow, respectively. The results of this study showed that the condition which affect the lowest physical load to the subject on the powered drilling task would be working with the 2.4kg of tool weight on the vertical work surface.

• Journal of Drive and Control
• /
• v.14 no.4
• /
• pp.1-8
• /
• 2017

The Down-the-Hole hammer is one of the pneumatic drill equipment used for grinding, drilling, and mining. One the advantages of which is that a reduction work efficiency at deep site are relatively small compared to other drilling methods. Due to the large vibration in the underground area, it is difficult to measure the performance of the hammer, and hammer testing requires substantial production cost and operating expenses so research on the development of the hammer is insufficient. Therefore, this study has developed a dynamic simulation model that apprehends the operating principles of an 8-inch DTH hammer and calculates performance data such as performance impact force, piston speed, and BPM. By using the simulation model, design factors related to strike force and BPM were selected, and the influence of each design factors on performance was analyzed through ANOVA analysis. As a result, be the most important for BPM and the strike force are position of upper port that push the piston in the direction of the bit and in BPM, the size of the empty space between the bits and the piston is the second most important design factor.

• Transactions of Materials Processing
• /
• v.13 no.3
• /
• pp.253-261
• /
• 2004

The machining technology for the brittle materials such as ceramics are applied to the fields of MEMS(micro electromechanical system) by the progress of new machining technologies such as Etching, Diamond machining, Micro drilling, EDM(Electro discharge machining), ECDM(Electro discharge machining), USM(Ultrasonic machining), LBM(Laser beam machining), EBM(Electron beam machining). Especially, the USM technology can be applied to the dieletric brittle materials such as silicon, borosilicate glass, silicon nitride, quartz and ceramics with high aspect ratio. The micro machining system with machining force controlled position servo is developed in this paper and the optimized ultrasonic machining algorithm is constructed by the force controlled position servo control. The load cell is adapted in the force measuring and the servo control algorithm, suit for the ultrasonic machining characteristics, is estabilished with using the PID auto-tunning functions at the PMAC system which is generally adapted in the field of robot industries. The precision force signal amplifier is constructed with high precision operational amplifier AD524. The vacuum adsorption chuck which is made of titanum and internal flow line is engraved, is used in the workpiece fixing. The mahining results by USM shows that there are some deviation between the force command and the actual machining force that the servo control algorithm should be applied in the machining procedures. Therefore, the constant force controlled position servo system is developed for the micro USM system and by the examination machining process in USM, the stable USM system is realized by tracking the average value of machining force.

• Journal of the Korean Society for Precision Engineering
• /
• v.24 no.12
• /
• pp.50-56
• /
• 2007

Femtosecond laser ablation of the Invar alloy and hole drilling for a shadow mask are studied. We used a regenerative amplified Ti-sapphire laser with a 1kHz repetition rate, 184fs pulse duration and 785nm wavelength. Femtosecond laser pulse was irradiated on the Invar alloy with air blowing at the condition of various laser peak power. An ablation characteristic of the Invar alloy was appeared non-linear at $125J/cm^2$ of energy fluence. For the application to a shadow mask, the hole drilling of the Invar alloy with the cross section of a trapezoidal shape was investigated. The ablated micro-holes were characterized using an atomic force microscopy(AFM). The optimal condition of hole pattern f3r a shadow mask was $4\;{\mu}m$ z-axis feed rate, 0.2mm/s circular velocity, $26.4{\mu}J$ laser peak power. With the optimal processing condition, the fine circular hole shape without burr and thermal damage was achieved. Using the femtoseocond laser system, it demonstrates excellent tool for the Invar alloy micro-hole drilling without heat effects and poor edge.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.6
• /
• pp.77-82
• /
• 2016

When drilling through Inconel 601 nickel-chromium-based alloys, a large amount of cutting oil is required to prevent tools from wear and fracturing due to heat buildup resulting from the high temperature resistance and toughness of this alloy. However, cutting oil supply has become a factor compromising the machining environment, and this has caused attention to shift to a more environmentally friendly cutting fluid supply system called minimum quantity lubrication (MQL). Our aim in this study was to find a more efficient drill processing method using MQL, and to verify its performance. To that end, we proposed a sealed cover, a step feed, and POSS-type cutting oil as measures to increase the effectiveness of MQL in view of the cutting force and tool wear, and established an improvement in efficiency using the proposed measures.