• Transactions of Materials Processing
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• v.13 no.3
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• pp.253-261
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• 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 of Manufacturing Process Engineers
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• v.14 no.6
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• pp.122-128
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• 2015

Recently, as the demand for high efficiency, multi-function machine tools has increased, domestic machine tool industries are investing in research and development for Gantry-Type Machining centers. In this thesis, for the purpose of evaluating machining accuracy and designing a machine tool structure, a simplified model of the main frame is suggested. The results show the general characteristics of the optimum design, and the approach is shown as practicable for the preliminary design analysis and improvement of a conceptual design of a Gantry-Type Machining center. This paper's results are expected to improve the static characteristics of Gantry-Type Machine centers. The three-dimensional finite element models proved that the modeling method might be applied to real machine tool structures.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2005.05a
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• pp.483-488
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• 2005

The complex three-dimensional miniature components are needed for a wide range of applications from the aerospace to the biomedical industries. To manufacture these products, micro machining that can make a high aspect ratio part and has good accuracy is widely researched. In this paper, cutting characteristics were analyzed in micro machining using cutting force coefficients, which are the specific cutting force for normal and frictional direction of rake surface. From measured cutting force in micro end milling, cutting condition independent cutting force coefficients were determined and used for analysing the characteristics of micro cutting. Using the cutting force coefficient, 써써써.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.3
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• pp.48-54
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• 2000

In this study the characteristics of chip formation of the cold drawn Bi-S free machining steels were assessed. And for comparison those of the cold drawn Pb-S free machining steel the hot rolled low carbon steel which has MnS as free machining inclusions and the conventional steels were also investigated. During chip formation the cold drawn free machining steels show relatively little change in thickness and width of chip compare to those of the conventional carbon steels. And a single parameter which indicates the degree of deformation during chip formation chip cross-section area ratio is introduced. The chip cross-section area ratio is defined as chip cross-section area is divided by undeformed chip cross-section area. The variational patters of the chip cross-section area ratio of the materials cut are similar to those of the shear strain values. The shear stress however seems to be dependent on the carbon content of the materials. The cold drawn Bi-S and Pb-S steels show nearly the same chip forming behaviors and the energy consumed during chip formation is almost same. A low carbon steel without free machining aids shows poor chip breakability due to its high ductility. By introducing a small amount of free machining inclusions such as MnS Bi, Pb or merely increasing carbon content the chip breakability improves significantly.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.6
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• pp.35-42
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• 2004

At the large-sized mold fer injection molding, the remaining gas in the mold causes some problems with final products. In order to solve these problems, air-bent was drilled on the surface of mold. However, this method leaves the scar on the surface of a product. Therefore, porous material was developed to the removal of remaining gas in this study. Porcerax II, which is a commercialized porous material, were developed in USA. It requires the electric discharge machining(EDM) process to make pores on the surface of the materials. The electric discharge machining (EDM) process, however, cause the increase of the time and cost for the fabrication of the mold. In this study, high speed machining(HSM) process was applied to the fabrication of porous mold without electric discharge machining(EDM) process. Some characteristics of the developed materials machined by high speed machining(HSM) and electric discharge machining(EDM) including air-permeability and porosity were compared with those of Porcerax II. Besides, in order to be applied to the molding process, hardness and tensile ＆ yield strength were compared between Porcerax II and developed materials.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.6 no.4
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• pp.130-137
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• 1997

The demand for wire-cut EDM is increasing rapidly in the die and tool making industry. In this study machining characteristics such as machining rate, surface roughness, hand drum form and hardness of machined material are investigated experimentally under the conditions varing pulse on time, pulse off time, peak voltage, wire tension after fixing other conditions in SKD 11 and brass and brass workpiece. It was found that various operating conditions had significant influences on machining characteristics. But the hardness of workpiece was uneffected by operating conditions. Also it was obtained experimentally that brass workpeice had better machinability than SKD 11 one.dition according to the current(Ip) in an electric spark machine : 1) Electrode is utilized Cu and Graphite. 2) Work piece is used the material of carbon steel. The condition of experiment is : 1) Current is varied 0.7(A) to 50(A) and the time of electric discharging to work piece in each time is 30(min) to 60(min). 2) After the upper side of work piece was measured in radius(5$\mu$m) of stylus analyzed the surface roughness to ade the table and graph of Rmax by yielding data. 3) Electro wear ratio is : \circled1Cooper was measured ex-machining and post-machining by the electronic balance. \circled2The ex-machining of graphite measured by it, the post-machining was found the data from volume $\times$specific gravity and analyzed to made its table and graph on ground the data. 4) In order to keep the accuracy of voltage affected to the work piece was equipped with the A.V. R and the memory scope was sticked to the electric spark machine. 5) In order to preserve the precision of current, to get rid of the noise occured by internal resistance of electric spark machine and to force injecting for the discharge fluid , it made the fixed table for a work piece to minimize the work error by means of one's failure during the electric discharging.

• Journal of Powder Materials
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• v.22 no.3
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• pp.163-168
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• 2015

Ti alloys are extensively used in high-technology application because of their strength, oxidation resistance at high temperature. However, Ti alloys tend to be classified very difficult to cut material. In this paper, The powder synthesis, spark plasma sintering (SPS), bulk material properties such as electrical conductivity and thermal conductivity are systematically examined on $Ti_2AlN$ and $Ti_2AlC$ materials having most light-weight and oxidation resistance among the MAX phases. The bulk samples mainly consisted of $Ti_2AlN$ and $Ti_2AlC$ materials with density close to theoretical value were synthesized by a SPS method. Machining characteristics such as machining time, surface quality are analyzed with measurement of voltage and current waveform according to machining condition of micro-electrical discharge machining with micro-channel shape.

• Transactions of Materials Processing
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• v.16 no.1 s.91
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• pp.15-19
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• 2007

This paper presents an integrated machining error compensation method based on captured images of tool deflection shapes in flat end-milling processes. This approach allows us to avoid modeling machining characteristics (cutting forces, tool deflections and machining errors etc.) and accumulating calculation errors induced by several simulations. For this, a high-speed camera captured images of real deformed tool shapes which were cutting under given machining conditions. Using image processes and a machining error model, it is possible to estimate tool deflection in cutting conditions modeled and to compensate for machining errors using an iterative algorithm correcting tool paths. This corrected tool path can effectively reduce machining errors in the flat end-milling process. Experiments are carried out to validate the approaches proposed in this paper. The proposed error compensation method can be effectively implemented in a real machining situation, producing much smaller errors.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.2
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• pp.104-111
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• 2004

Ultrasonic machining is a non-thermal, non-chemical, md non-electorial material removal process, and thus results in minimum modifications in mechanical properties of the brittle material during the process. Also, ultrasonic machining is a non-contact process that utilize ultrasonic vibration to impact a brittle material. In this research characteristics of micro-hole machining for brittle materials by ultrasonic machining(USM) process have been investigated. And the effect of ultrasonic vibration on the machining conditions is analyzed when machining fir non-conductive brittle materials using tungsten carbide tools with a view to improve form and machining accuracy.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.685-688
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• 2005

In the micro electrochemical machining (MECM) using ultra short pulses, the machining rate is closely related to the tool electrode area. The machining rate varies according to the machining depth or the immersion depth. When using insulated tool electrodes, those depths do not matter. In addition, micro structures with high machining depth can be fabricated because the machining characteristics do not vary with the machining depth. Another advantage of insulated electrodes is prevention of taper shape. Micro structures with high machining depth or high aspect ratio were fabricated using insulated tool electrodes.