Micro trench structures are applied in gratings, security films, wave guides, and micro fluidics. These micro trench structures have commonly been fabricated by micro electro mechanical system (MEMS) process. However, if the micro trench structures are machined using a diamond tool on large area plate, the resulting process is the most effective man- ufacturing method for products with high quality surfaces and outstanding optical characteristics. A nonferrous metal has been used as a workpiece; recently, and hybrid materials, including polymer materials, have been applied to mold for display fields. Thus, the machining characteristics of polymer materials should be analyzed. In this study, machining characteristics were compared between nonferrous metals and polymer materials using single crystal diamond (SCD) tools; the use of such materials is increasing in machining applications. The experiment was conducted using a square type diamond tool and a shaper machine tool with cutting depths of 2, 4, 6 and 10 µm and a cutting speed of 200 mm/s. The machined surfaces, chip, and cutting force were compared through the experiment.

In this paper, we describe experiment results using a vibration assisted hybrid femtosecond laser (λ:795 nm) ultra- precision machining system. The hybrid system we have developed is possible that optical focal point of the femtosec- ond laser constantly and frequently within the range of PZT(piezoactuator) vibrator working distance. Using the hybrid system, We have experimented on brass and studied about differences of result of hole aspect ratio compare to general experiment setup of femtosecond laser system. Aspect ratio of a micro hole on brass is increased as 54% with 100 Hz vibration frequency and surface roughness of the side wall also improved compare to non-vibration.

Mirror surface machining for large area flattening in the display field has a problem such as a tool wear and a increase in machining time due to large area machining. It should be studied to decrease machining time and tool wear. In this paper, multi-tool machining method using a PCD tool and a SCD tool was applied in order to decrease machining time and tool wear. Machining characteristics (cutting force, machined surface and surface roughness) of PCD tool and SCD tool were evaluated in order to apply PCD tool to flattening machining. Based on basic experi- ments, the PCD/SCD multi-tool method and the SCD single-tool method were compared through surface roughness and machining time for appllying large area mold machining.

목적: 본 연구의 목적은 새롭게 개발하여 국산화한 안경테용 셀룰로오스 아세테이트(Cellulose Acetate; CA) 소재의 가공품질 및 생산성 향상을 위해 절삭성에 관한 연구를 수행하였다. 방법: 다양한 절삭 및 이송속도의 변화조건 하에서 절삭성이 평가되었다. CA 소재의 절삭실험은 절삭력, 표면조도 및 칩형상 등의 분석이 이루어졌으며, 이를 통해 절삭성을 평가하였다. 결과: 주축회전수 20,000과 30,000 rpm을 제외하고 고속영역에서 절삭력이 낮게 나타났으며, 고속회전 시 표면조도가 저속회전 조건 보다 우수하였다. 절삭력과 표면조도의 상관관계는 고속회전 조건에서는 크지 않은 것으로 나타났다. 결론: 국산화를 위해 새롭게 개발한 안경테용 CA 소재의 고품위 가공의 절삭성 평가를 수행한 결과 주축 회전수 20,000과30,000rpm을 제외하고 고속영역에서 절삭성이 양호하였으며, 표면조도는 날당이송 0.1mm 이외의 조건에서 주축회전수가 증가할수록 양호해졌고, 칩형상도 고속회전 및 저이송 조건으로 갈수록 균일 한 형태의 칩이 발생됨을 알 수 있었다. 이상과 같은 실험결과를 종합하여 새롭게 개발된 CA 소재의 절삭성을 평가할 수 있는 기초자료를 확보할 수 있었다.

The multi-direction firing of the optical fiber has been required to induce wider damage zone during the laser-assisted surgery. The optical fibers tend to have poor machinability because of its hardness and brittleness. In this study, we employed the ECDM to fabricate the tip of the optical fiber in cone-shape. The con-shaped tip made the multidirectional emission of the light at the distal end of the fiber. The result showed that the lower electrolyte concentration enhanced the surface quality. The optimal concentration of electrolyte was 15% to make high quality surface of optical fiber tip in this experimental condition. When the voltage was more lower, surface quality had been become better. The suitable voltage was 30V for the effective process time.

Recently, various efforts to make more speedy and precision machine tool to improve productivity and also various efforts to solve environmental problem are going on, so that dry cutting in manufacturing industry, which needs environmental conscious design and development of manufacturing technique, is becoming a very important assignment to solve. Because dry cutting does not use cutting fluid, we need other methods that can be used instead of cutting fluid, which does cooling, lubricating, chip washing, and anti-corrosion. Especially, because turning is a continuous work, the consideration of tool life and surface roughness due to continuous heat and poor lubrication is important. The purposes of this paper are the consideration of how well the compressed air can work instead of cutting fluid, and also the development of the method to select the optimum machining condition by the minimum numbers of experiments through the Taguchi method.

Small and medium companies have few dedicated employees for process planning and analyzing. They have many defects in their operational processes which result in less productivity. This research analyze a process of small company, which makes a hole and a round for gear parts. We found that the drilling operation is a bootle-neck operation and propose a revised general machine for drilling operation. The legacy drilling operation is performed as follows. First, a operator drills a half hole of a part and turns the part upside down. Then he drills a rest hole of the part. The operation needs more efforts than other operations. Therefore a productivity of the factory depends on that of the drilling operation. We developed a horizontal multi-drilling machine for the drilling operation. The machine has the drilling tool heads and takes three parts and makes a hole at the same time. It eliminates human operation in the middle of drilling, We also developed clamping jig for holding parts tightly. The proposed machine reduces the total operation time and enhances the productivity of the factory. The process capability index also increased from 6.8 to 9.6.

This study presents a single machine scheduling algorithm to minimize total cost(lateness cost, earliness cost and failure cost) by controlling machining speed. Generally, production scheduling uses the information of process planning and machining speed

The liquid-phase sintering method was used to prepare a glass lens forming core composed of SiC-Al2O3-Y2O3. Spark plasma sintering was used to obtain dense sintered bodies. The sintering characteristics of different SiC sources and compositions of additives were studied. Results revealed that, owing to its initial larger surface area, α-SiC offers sinterability that is superior to that of β-SiC. A maximum density of 3.32 g/cm3 (theoretical density [TD] of 99.7%) was obtained in α-SiC-10 wt% (6Al2O3-4Y2O3) sintered at 1850˚C without high-energy ball milling. The maximum hardness and compression stress of the sintered body reached 2870 Hv and 1110 MPa, respectively. The optimum ultra-precision machining parameters were a grinding speed of 1243 m/min, work spindle rotation rate of 100 rpm, feed rate of 0.5 mm/min, and depth of cut of 0.2 μm. The surface roughnesses of the thus prepared final products were Ra = 4.3 nm and Rt = 55.3 nm for the aspheric lens forming core and Ra = 4.4 nm and Rt = 41.9 for the spherical lens forming core. These values were found to be sufficiently low, and the cores showed good compatibility between SiC and the diamond-like carbon (DLC) coating material. Thus, these glass lens forming cores have great potential for application in the lens industry.

This paper presents a study of the influence of cutting parameters on surface finish obtained by face milling. Cutting conditions have significantly great effect on surface quality in high-precision machining. Fundamentally, surface roughness are strongly correlated with cutting parameters such as feed rate, cutting speed and depth of cut. Optimal selection of the cutting parameters can obtain better surface roughness. Therefore, optimization of the cutting parameters in a face milling based on the parameter design of the Taguchi method is adopted in this paper to improve surface roughness. And optimal cutting parameters based on the results of the S/N ratio and ANOVA analyses to performance high-precision machining is obtained and verified by confirmation test.

인체의 특성을 고려한 맞춤형 자유 곡면은 현대생활의 많은 부분에서 필요하지만 그 개발은 복잡하여 수리적으로 단순한 모델링을 하기가 어렵다. CAD를 이용하여 모델링을 하기도 하지만 이런 경우 특성점을 입력하여야 하는데 자유 곡면에서는 특성점을 찾기가 어렵기 때문에 역공학을 이용하여 모델링한다. 본 논문에서는 자유 곡면으로서 인체의 특성에 잘 맞는 개인 맞춤형 곡면을 모델링하여 이를 공작기계에서 가공하는 방법에 대하여 연구한다. 자전거의 안장은 자유 곡면으로서 개인의 신체특성에 맞도록 설계하며 역공학의 방법을 이용하여 모델링한다. CAD를 이용하여 수정하고 이를 가공하기 위한 공구경로를 생성한다. 가공경로를 그래픽 시뮬레이션으로 검증 하고 이를 3축 공작기계에서 생산하여 안장곡면 생산을 위한 금형개발의 기초로 하는 것이 본 연구의 주요 내용이다.

High-pressure abrasive entrained jet have rapidly become important machining technology over the last two decades. However, suspension jet by high-pressure has been recently developed for packaging sawing. Ideally, diamond materials should be used for components in abrasive water-jet systems that are subject to high erosive conditions. Using the diamond orifices improve maintenance and extend wear part life. This paper gives insights to using an abrasive suspension jet with diamond orifice. The influences of orifice material and orifice design are evaluated.

In manufacturing industry, cutting parameters have an influence on reducing the production cost and time and deciding the quality of a final product However, owing to governmental regulations and the change of owner's cognizance, the machining safety becomes important in those fields relatively. The paper presents an intelligent operation planning system considering machining safety for milling operations. The main issue of the system is to determine the cutting parameters in achieving a balanced consideration of productivity and worker's safety. The detailed algorithm and functions of the developed system is introduced and then discussed.

To satisfy the demand of higher cutting performance, mechanical properties with tungsten carbide (WC-Co) tool materials were investigated. Hardness and transverse rupture strength with WC grain size, Co content and density were measured. Compared to H, K, and S manufacture maker as tungsten carbide (WC-Co) tool materials were used for high-speed machining of end-milling operation. The three tungsten carbide (WC-Co) tool materials were evaluated by cutting of STD 11 cold-worked die steel (HRC25) under high-speed cutting condition. Also, tool life was obtained from measuring flank wear by CCD wear measuring system. Tool dynamometer was used to measure cutting force. The cutting force and tool wear are discussed along with tool material characteristics. Consequently, the end-mill of K, H manufacture maker showed higher wear-resistance due to its higher hardness, while the S maker endmill tool showed better performance for high metal removal.

  Surface roughness is an important factor to evaluate machined parts in precision machining. This is the major measure of surface quality. This research sets up experiments to select the factors which affect surface roughness in the machining of inclined

Intelligent machines respond to external environments on the basis of decisions that are made by sensing the changes in the environment and analyzing the obtained information. This study focuses on the construction of a knowledge base which enables decision making with that information. Approximately 70% of all errors that occur in machine tools are caused by thermal error. In order to proactive deal with these errors, a system which measures the temperature of each part and predicts and compensates the displacement of each axis has been developed. The system was built in an open type controller to enable machine tools to measure temperature changes and compensate the displacement. The construction of a machining knowledge base is important for the implementation of intelligent machine tools, and is expected to be applicable to the network based intelligent machine tools which look set to appear sooner or later.

The KASINICS (Korea Astronomy and Space science Institute Near Infrared Camera System) is a ground-based near-infrared (NIR) imaging instrument. KASINICS has offner relay optics to reduce unwanted infrared light. For the offner optics, we adopted an ultra precision machining process which is installed at KBSI (Korea Basics Science research Institute). Since the offner relay optics is made of aluminum 6061 metal material, we did several tests to reach the specification. We found that a 0.497mm radius nose bite and 220m/min machining speed are best tool and condition to make this offner optics with the precision machine. In this paper, we report the technical method of ultra precision machining and results of the KASINICS offner optics.

  Machining processes produce high accurate metallic parts in metal working industries. Lubrication for machining enhances quality of machined surface and it prolongs the life of cutting tools. Since lubricant is poisonous to human body and environment, i

Influences of machining on magnetic properties of soft magnetic composites (SMC's) with addition of two kinds of binder, i.e., organic binder and inorganic one, were investigated. Machining does not affect DC magnetic properties of the SMC compacts. This can be ascribed to their particular structure in which the ironpowder particles are highly isolated by the binder. On the other hand, decrease in resistivity and resultant increase in eddy current loss was confirmed in the machined compacts containing inorganic binder. It is supposed that the brittleadditive binder existing between the iron particles is partly broken, and iron-to-iron contact is formed on the machined surface.

Aluminum-based composites reinforced with various amounts of were produced by powder metallurgy (P/M). The machinability properties of were determined by means of cutting forces and surface roughness. Machining tests were carried out by using PCD and K10 tools. Increasing of volume fraction in the matrix resulted in a decrease of the surface roughness and turning forces. PCD cutting tools showed better cutting performance than K10 tools.