Journal of the Korean Society of Manufacturing Technology Engineers (한국생산제조학회지)

The Korean Society of Manufacturing Technology Engineers (한국생산제조학회)
권호 표지
DOI QR코드

DOI QR Code

A Study On Prediction Model of Cutting Conditions for Draft Angle Control

마이크로금형 구배각 제어를 위한 절삭가공조건 예측모델에 관한 연구

  • 조지현 (인천대학교 대학원 기계시스템공학부) ;
  • 송병욱 (인천대학교 대학원 기계시스템공학부) ;
  • 서태일 (인천대학교 기계시스템공학부)
  • Received : 2012.05.19
  • Accepted : 2012.06.12
  • Published : 2012.06.15
Download PDF
⟨ Previous Next ⟩

Abstract

It is very difficult to determine suitable cutting conditions in order to obtain accurate cutting profiles because machining errors caused by tool deflection depend upon cutting conditions. In this study the relationship between real cutting profiles (inclined shapes and machining errors) and cutting conditions was modeled in order to fabricate draft angle on micro molds. CCD (Central Composite Design) of DOE (Design Of Experiment) and RSM (Response Surface Method) were applied in order to model the relationship between cutting conditions and machining errors. In order to use CCD the range of radial depth of cut was chosen by $10-90{\mu}m$ and the range of feedrate was chosen by 200-300mm/min, and 9 points of cutting conditions were chosen inside determined ranges. Then, actual cutting processes were carried out as respect to 9 points of cutting conditions, draft angles and real cutting profiles were measured on cutting profiles, each response surface function was determined by conducting response surface analysis and the functions were represented by 3-dimensional graphs, contour lines and $101{\times}101$ matrices. Consequently it is possible to determine suitable cutting conditions in order to obtain arbitrary given draft angles and cutting profiles by using modeling. To validate proposed approach in this study suitable cutting conditions were determined by modeling in order to obtain arbitrary given draft angle and cutting profile, and actual cutting processes were carried out. About 95% of good agreement between predicted and measured values was obtained.

Keywords

References

  1. Min, S. K., Lee, S. W., Lee, D. J., Lee, E. S., and Jae, T. J., 2002, "A Study on the Machining Characteristics for Micro Barrier Ribs by using Micro Endmilling," Journa of the Korean Society of Machine Tool Engineers, Vol. 11, No. 3, pp. 14-20.
  2. Donfeld, D., Min, S., and Takeuchi, Y., 2006, "Recent Advances in Mechanical Micromachining," Annals of the CIRP, Vol. 55, No. 2, pp. 745-768. https://doi.org/10.1016/j.cirp.2006.10.006
  3. Chae, J., Park, S. S., and Freiheit, T., 2006, "Investigation of Micro-cutting Operations," Int. J. of Machine Tools & Manufacture, Vol. 46, No. 3-4, pp. 313-332. https://doi.org/10.1016/j.ijmachtools.2005.05.015
  4. Kline, W. A., DeVor, R. E., and Lindberg, J. R., 1982, "The Prediction of Cutting Forces in End Milling with Application to Cornering Cuts," Int. J. Mach. Tool Des. Res., Vol. 22, No. 1, pp. 7-22. https://doi.org/10.1016/0020-7357(82)90016-6
  5. Sabberwal, A. J. P., 1961, "Chip Section and Cutting Force during the Milling Operation," Annals of CIRP, Vol. 10, No. 3, pp. 197-203.
  6. Lim, J. S., Cho, H. J., and Seo, T. I., 2010, "Tool Deflection Estimation in Micro Flat End-milling using Finite Element Method," Journa of the Korean Society of Machine Tool Engineers, Vol. 19, No. 4, pp. 489-503.
  7. Lo, C. C., and Hsiao, C. Y., 1998, "CNC Machine Tool Interpolator with Path Compensation for Repeated Contour Machining," Computer-Aided Design, Vol. 30, No. 1, pp. 55-62. https://doi.org/10.1016/S0010-4485(97)00053-5