• Korean Journal of Computational Design and Engineering
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• v.6 no.4
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• pp.263-270
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• 2001

In stamping-die manufacturing, the first step is to build die patterns for lost wax casting process. A recent industry trend is to manufacture the die pattern using 3-axis NC machining. This study identifies technical considerations of the pattern machining caused by the characteristics of Styrofoam material, and proposes technical methods related to establishing a process plan and generating tool paths for optimizing the pattern machining. In this paper, the process plan includes the fellowing three items: 1) deter-mining a global machining sequence-a sequence of profile, top, bottom machining and two set-ups, 2) extracting machining features from a pattern model and merging them, and 3) determining a machining sequence of machining features. To each machining feature, this study determines the machining start point, generates the approach tool path, and proposes a tool path linking method fur reducing the distance of the cutter rapid motion. Finally, a smooth tool path generation and an automatic feedrate adjustment (AFA) method are introduced far raising the machining efficiency.

• 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.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.3
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• pp.69-78
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• 2001

This paper presents a process and operation planning system and an NC code post-processor for effective machining of press dies for production of cars. Based on the machining feature, major parts of press dies are categorized into 15 groups and a standard process plan is defined for each group. The standard process plan consists of a series of processes where a process is defined as a group of operations that can be done with one setup. Details such as cutting tools, cutting conditions, and tool paths are decided at the operation planning stage. At the final stage of process and operation planning, the NC code post-processor adjusts feedrates along the tool path to reduce machining time while maintaining the quality. The adjustment rule is selected based on the machining load estimated by virtual machining.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.10
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• pp.52-59
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• 2006

Micro electrical discharge machining (EDM) and micro electrochemical machining (ECM) were studied for the fabrication of micro structures. Micro EDM has been used to machine micro structures from metals. However, since the tool wear is inevitable during the machining, the tool wear is drawback for the precision machining. Micro ECM is also used for micro machining and produces better surface quality than that of micro EDM. Moreover, since tool electrodes are not worn out, micro ECM is suitable for the precision micro machining. However, the machining rate is lower than that of micro EDM. In this paper, therefore, the hybrid machining process which uses micro EDM as roughing and micro ECM as finishing is introduced. By using this hybrid machining, a hemisphere with $100\;{\mu}m$ radius was fabricated and the efficiency of the process was investigated experimentally.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.100-105
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• 2003

With the recent development of machining technology, high speed machining process is widely used for-the mold and difficult-to -cut-materials machining since it allows achieving high productivity and surface quality. However, during the high speed machining process, high cutting speed and feed rate can cause abrupt tool life decrease due to rapid rising of the cutting tool temperature. Such situation may cause increase of machining cost. Thus, in this study, developed optimization algorithm is applied to determine optimal machining variables for multiple high speed machining. The R-T characteristic curve for machining economics problems with a linear-lorarithmic tool life model is determined by applying sensitivity analysis. finally, a series of high speed machining experiments are performed to determine the desired optimal machining variables, and the results are analyzed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.10a
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• pp.279-280
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• 2006

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.10a
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• pp.637-638
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• 2006

• Journal of the Korean Society for Precision Engineering
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• v.28 no.7
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• pp.761-768
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• 2011

The large surface micro machining system includes the equipments and processes for manufacturing the ultra precision micro patterned products with large surface through the mechanical machining. Recent major issue on the micro machining technology may be the development of optical parts for the back light unit of display which has the largest market. This special issue makes up with three parts; the large surface micro machining system and machine, machining process and forming process. In this paper, the state-of-the-art and core technology of large surface micro machining system is introduced with focus on the manufacturing technology for the back light unit of LCD TV. Then, some research results on the development of a roll die lathe is introduced which involves the concept of machine design, improvement of thermal characteristics in the spindle system, improvement of relative parallelism and straightness between spindle system and long stroke feed table, machining of micro pitch patterns. Finally, the direct forming process is introduced as the future work in the large surface micro machining field.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.1
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• pp.22-27
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• 2004

Recently, environmental pollution has become a significant problem in industry and many researchers have investigated in order to preserve the environment. Environmentally conscious machining and technology have more important position in machining process, because cutting fluid has bad influence on the environment in milling process. This research is the experimental study on high speed machining of aluminum alloys through environmentally conscious machining. In this study, the surface roughness and chip appearance was investigated in the machining of aluminum alloys by dry machining, using cutting fluid and oil mist.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.12
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• pp.14-20
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• 1998

Cutting fluid is a factor which has big effects on both machinability and environment in machining process. The loss of cutting fluids may be reduced by the optimization of machining parameters in process planning. In this study, the environmental impact of fluid loss is analyzed. The fluid loss models in milling process are constructed with the machining parameters. The models are utilized to obtain the optimal machining parameters to minimize the fluid loss. The factors with significant effects on the fluid loss are analyzed by ANOVA test. Finally, optimal parameters are suggested considering both machining economics and environmental impact. This study is expected to be used as a part of a framework for the environmental impact assessment of machining process.