• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.8
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• pp.1951-1962
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• 1993

The creation process of a typical machined surface is treated here as a dynamic system. An investigation is carried out to establish a relationship between the characteristics of cutting force fluctuations that cause vibration response of the tool-workpiece system and the formation of surface in face cutting by sintered carbide cutting tool. Cutting force is measured and analyzed in frequency domain. The power spectral densities of cutting force give a useful information in surface generation and it can be used to find out the control factor of surface roughness. The terms, PSD ratio & Normalized spindle frequency PSD, are defined and when the value of power in spindle frequency is absolutely little but relatively large, it is obtained high accuracy surface roughness. The aim of this research is to find surface profile by measured and analyzed cutting force signals. The simulation of surface generation gives the comprechension of its mechanism and help to predict and control the surface quality. In this study, it is suggested what informations about surface generation can be acquired from the cuttuing force signal and an way of generating a better surface.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.5
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• pp.590-597
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• 1985

A recursive geometric adaptive control method to compensate for machining straightness error in the finished surface due to tool deflection and guideway error generated by end milling process is developed. The relationship between the tool deflection and the feedrate is modeled by a modified Taylor's tool life equation. Without a priori knowledge on the variations off cutting parameters, time varying parameters are then estimated by an exponentially windowed recursive least squares method with only post-process measurements of the straightness error. The location error is controlled by shifting the milling bed in the direction perpendicular to the finished surface and adding a certain amount of feedrate with respect to the tool deflection model before cutting. The waviness error is compensated by adjusting the feedrate during machining. Experimental results show that location error is controlled within a range of fixturing error of the bed on the guideway and that about 60% reduction in the waviness error can be achieved within a few steps of parameter adaption under wide operating ranges of cutting conditions even if the parameters do not converge to fixed values.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.634-639
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• 2003

It has been studied the flow near a rotating disk with surface topography. The system Ekman number is assumed very small, i.e., $E[{\equiv}\frac{\nu}{{\Omega}^{\ast}L^{\ast2}}]<<1$ in which $L^{\ast}$ denotes a disk radius, ${\nu}$ kinematic viscosity of the fluid and ${\Omega}^{\ast}$ angular velocity of the basic state. Disk surface has a sinusoidal topographic variation along radial coordinate, i.e., $z={\delta}cos(2{\pi}{\omega}r)$, where ${\delta}$ and ${\omega}$ are, respectively, nondimensional amplitude and wave number of the disk surface. Analytic solutions, being useful over the parametric ranges of ${\delta}{\sim}O$( $E^{1/2}$ ) and ${\omega}{\leq}O$ ( $E^{1/2}$ ), are secured in a series-function form of Fourier-Bessel type. An asymptotic behavior, when $E{\rightarrow}0$, is clarified as : for a disk with surface roughness, in contrast to the case of a flat disk, the azimuthal velocity increases in magnitude, together with the thickening boundary layer. The radial velocity, however, decreases in magnitude as the amplitude of surface waviness increases. Consequently, the overall Ekman pumping at the edge of the boundary layer remains unchanged, maintaining the constant value equal to that of the flat disk.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.7
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• pp.15-24
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• 2021

In this paper, to analyze the types of surface morphology error according to factors that cause machining error, the experiments were conducted in the ultra-precision diamond machine using a diamond tool. The factors causing machining error were classified into the pressure variation of compressed air, external shock, tool errors, machining conditions (rotational speed and feed rate), tool wear, and vibration. The pressure variation of compressed air causes a form accuracy error with waviness. An external shock causes a ring-shaped surface defect. The installed diamond tool for machining often has height error, feed-direction position error, and radius size error. The types of form accuracy error according to the tool's errors were analyzed by CAD simulation. The surface roughness is dependent on the tool radius, rotational speed, and feed rate. It was confirmed that the surface roughness was significantly affected by tool wear and vibration, and the surface roughness of Rz 0.0105 ㎛ was achieved.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.6
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• pp.630-635
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• 2014

This study aims to develop a PZT-driven depth adjustment device with a flexure hinge and to investigate its static/dynamic characteristics. This device will be applied to rapidly and accurately trace a flat surface with slight waviness of up to several hundreds of micrometers in magnitude. One typical example is to cut a film coated on a steel plate. A depth control system composed of PMAC, PZT/PZT amplifier, flexure hinge/knife, and laser displacement sensor is implemented on a desktop three-axis machine and an actual cutting test is conducted on a steel workpiece with a sinusoidal-wavy surface. It is verified that the dynamic characteristics of the device limit the maximum cutting speed and depth precision.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.7
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• pp.653-657
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• 2015

A numerical investigation to simulate the selective growth of silicon-germanium quantum-dots via local surface diffusivity enhancement is presented. A nonlinear equation for the waviness evolution of film surface is derived to consider the effects of spatially-varying diffusivity, influenced by a surface temperature profile. Results show that the morphology of the initially planar film shapes into an undulated surface upon perturbation, and a steady-state solution describes a fully grown quantum-dot. The present study points toward a fabrication technique that can obtain selectivity for self-assembly.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.155-160
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• 2002

Recently, the development of aerospace and automobile industries has brought new technological challenges, rebated to the growing complexity of products and the new geometry of the models. High speed milling with a 5-Axis milling machine has been widely used fur 3D sculptured surface parts. When turbine blades are machined by a 5-axis milling, their thin and cantilever shape causes vibrations, deflections and twists. Therefore, the surface roughness and the waviness of the workpiece are not good. In this paper, the effects of cutter orientation and the lead/tilt angle used to machine turbine blades with a 5-axis high speed ball end-milling were investigated to improve geometric accuracy and surface integrity. The experiments were performed using a lead/tilt angle of 15$^{\circ}$ to the workpiece with four cutter directions such as horizontal outward, horizontal inward, vertical outward, and vortical inward directions. Workpiece deflection, surface roughness and the machined surface were all measured with various cutter orientations such as cutting directions, and lead/tilt angle. The results show that the best cutting strategy for machining turbine blades with a 5-axis milling is horizontal inward direction with a tilt angle.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.53-60
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• 2002

Recently, the development of aerospace and automobile industries brought new technological challenges, related to the growing complexity of products and new geometry models. High speed machining using 5-Axis milling machine is widely used for 3D sculptured surface parts. 5-axis milling of turbine blade generates the vibration, deflection and twisting caused from thin and cantilever shape. So, the surface roughness and the waviness of workpiece are not good. In this paper, The effects of cutter orientation and lead/tilt angle in 5-Axis high speed ball end-milling of turbine blade were investigated to improve the geometric accuracy and surface integrity. The experiments were performed at lead/tilt angle $15^{\circ}$ of workpiece with four cutter directions such as horizontal outward, horizontal inward, vertical outward, and vertical inward. Workpiece deflection, surface roughness and machined surface were measured with various cutter orientations such as cutting direction, and lead/tilt angle. The results show that when 5-axis machining of turbine blade, the best cutting strategy is horizontal inward direction with tilt angle. The results show that when 5-axis machining of turbine blade, the best cutting strategy is horizontal inward direction with tilt angle.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.5
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• pp.35-42
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• 2014

The influence of sine wave striated surface roughness on load carrying capacity of a bearing is studied for thin film effect of slider bearing. A Reynolds equation appropriate for slider bearing is used in this paper for analysis and it is discussed using finite difference method of central difference scheme. For a slider bearing with sine wave simple roughness form, several parameters such as pressure, load capacity and shear stress of the bearing can be obtained and also this results can be stored in sequential data file for latter analysis. After all, their distribution can be displayed and analyzed easily by using the matlab GUI technique. The parameters such as amplitude, number of waviness and slope of the surface are used for discussing the load carrying capacity of the rectangular bearing. The results reported in this paper should be applied to the other slider bearing such as rectangular or round embossed surface of slider bearing.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.3
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• pp.408-413
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• 2013

Micro-features such as grooves and lenses, which perform optical functions in flat displays, should be manufactured with a good form accuracy because this is directly related to their optical performance. As the size of the display increases, it is very difficult to maintain a high relative accuracy because of the inherent geometric errors such as the waviness of a large-area plate. In this paper, the optical effect of these geometric errors is investigated, and surface-referenced micro-grooving to measure and compensate for such geometric errors on line is proposed to improve the form accuracy of the micro-grooves. A PZT-based fast depth adjustment servo system is implemented in the tool holder to maintain a uniform groove depth in reference to the wavy surface. Through experiments, the proposed method is shown to be an efficient way to produce high-quality micro- grooves on a wavy die surface.