In this research, a new structure of an asymmetric piston dedicated machining center is developed. By applying 2 linear motors in this machine, the slide unit structure could be simplified by comparing to the ball screw method, resulting in easier maintenance of the machine and enabling simultaneous machining in 2 axes and high-speed precision machining. In addition, a dedicated HMI for the asymmetric piston is developed to support efficient operation by workers, allowing them to verify product quality and take necessary actions. It is confirmed that by fully utilizing control libraries and productive programming languages, immediate response to future demands could be achieved. Through speed control loop performance testing, it is confirmed that applying feedforward function could improve the response speed, control accuracy, and stability of the speed control loop. The application of polynomial interpolation and Newton interpolation in the actual machining of asymmetric pistons confirmed the achievement of dynamic machining precision at high speeds. The developed machine and HMI are expected to contribute significantly to the efficiency, productivity, and improvement of product quality in the machining of asymmetric pistons.
When the product is taken out after the injection process, the surface of the product and the mold are attached and to separate them, it is necessary to consider the frictional force between the mold surface and the product surface. Therefore, to reduce the frictional force, a subtraction gradient for the rib shape is generally applied, and a lapping process is performed to improve the surface roughness of the rib shape surface of the processed mold. Therefore, research is needed to improve the surface roughness when processing the rib. In this study, slotting processing was applied to improve surface roughness when processing ribs. Slotting processing is a processing method that removes material through the feed motion of the tool, and processing is possible regardless of the aspect ratio of the processing shape. A slotting tool was developed for rib machining and a comparative experiment with electric discharge machining was performed. Also after processing, the surface roughness and processing time were compared and analyzed, and the improved surface roughness and fast processing time characteristics of the slotting processing compared to electric discharge processing were confirmed.
Selective laser melting (SLM) can produce a layer of a metal powder and then fabricate a three-dimensional structure by a layer-by-layer method. Each layer consists of several lines of molten metal. Laser parameters and thermal properties of the materials affect the geometric characteristics of the melt pool such as its height, depth, and width. The geometrical characteristics of the melt pool are determined herein by optical microscopy and three-dimensional bulk structures are fabricated to investigate the relationship between them. Powders of the commercially available Fe-based tool steel AISI H13 and Ni-based superalloy Inconel 738LC are used to investigate the effect of material properties. Only the scan speed is controlled to change the laser parameters. The laser power and hatch space are maintained throughout the study. Laser of a higher energy density is seen to melt a wider and deeper range of powder and substrate; however, it does not correspond with the most highly densified three-dimensional structure. H13 shows the highest density at a laser scan speed of 200 mm/s whereas Inconel 738LC shows the highest density at 600 mm/s.
Carbon fiber reinforced plastics are typical examples of carbon fiber, which retain high strength and high strength at high temperatures. Also, it is applied to various fields, such as the structure of the aircraft, automobile, and the core industries. CFRP machining methods include machining tools such as cutting machining and laser machining. In this thesis, a tool dynamometer and tool microscope were used to measure the cutting characteristics of various cutting conditions and tool wear and tool wear. As a result, the cutting force of the new shape drill (lower shape drill) was measured higher than other tools, the amount of tool wear was the lowest, and it was found that a good machined surface was obtained.
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.