Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which sa...Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which satisfy the stiffimss and rotational speed required to the spindle. A general full factorial design method was used to verify some factors that affect the natural frequency of a spindle. It is verified that the shorter shaft length and bearing span length represent the higher natural frequency, and there are some effects according to the change in the levels of factors. The detailed spindle dimension is determined by applying an EVD method, which can define the optimal bearing position through considering the limiting condition. Based on the estimated regression model, the optimal spindle size and bearing distance that can improve the primary natural frequency are obtained, and the influence of design factors on the natural frequency is also analyzed.展开更多
To enhance machining efficiency,tool change time has to be reduced.Thus,for an automatic tool changer attached to a machining center,the tool change time is to be reduced.Also the automatic tool changer is a main part...To enhance machining efficiency,tool change time has to be reduced.Thus,for an automatic tool changer attached to a machining center,the tool change time is to be reduced.Also the automatic tool changer is a main part of the machining center as a driving source.The static attributes of the automatic tool changer using the commercial code,ANSYS Workbench V12,were tried to interpret.And the optimum design of automatic tool changer arm was proposed by performing the multi-stage optimum design.The shape optimization of the automatic tool changer was proposed and the result was verified to obtain acceptable improvements.It is possible to obtain an optimized model in which the maximum deformation,maximum stress,and mass are reduced by 10.46%,12.89% and 9.26%,respectively,compared with those of the initial model.Also,the results between conventional method by the design of experiments and proposed method by the multi-stage optimum design method were compared.展开更多
Laser assisted machining （LAM） has difficulties in estimating temperature after applying a LAM process due to its very small heat input area, large energy and movement. In particular, in the case of laser assisted t...Laser assisted machining （LAM） has difficulties in estimating temperature after applying a LAM process due to its very small heat input area, large energy and movement. In particular, in the case of laser assisted turning （LAT） process, it is more difficult to estimate the temperature after preheating because it has a shape of ellipse when a laser heat source is rotated. A prediction method and thermal analysis method for heat source shapes were proposed as a square shaped member was preheated. The temperature distribution was calculated according to the rotation of the member. Compared with the results of the former study, the maximum temperature of the calculation results, 1 407.1 ℃, is 8.5 ℃ higher than that of the square member, which is 1 398.6 ℃. In a LAT process for a square member, the maximum temperature is 1 850.8 ℃. It is recognized that a laser power control process is required because square members show a maximum temperature that exceeds a melting temperature at around a vertex of the member according to the rotation.展开更多
Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to ...Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to obtain a positive motion from the follower using a rotating cam,its shape should be correctly designed and manufactured.The development of an adequate CAD/CAM system for a cam profile CNC grinding machine is necessary to manufacture high-precision cams.The purpose of this study is the development of a CAD/CAM system and profile measuring device for a CNC grinding machine to obtain an optimal grinding speed with a constant surface roughness.Three types of disk cams were manufactured using the proposed algorithm and procedures to verify effectiveness of the developed CAD/CAM system.展开更多
For laser assisted machining,shape of preheating laser heat source is changed irregularly because of complexity of material shape.So,the preheating temperature should be controlled by adjusting the feed rate or the la...For laser assisted machining,shape of preheating laser heat source is changed irregularly because of complexity of material shape.So,the preheating temperature should be controlled by adjusting the feed rate or the laser power.Thermal analyses of the laser assisted machining process for inclination planes were performed.By analyzing the obtained temperature profile,a proper feed rate control method was proposed according to the inclination angles.In addition,the temperature distribution of the cross section after feed rate control was predicted.The correlation equation between inclination angles and adjusted proper feed rate was proposed.The results of this analysis can be used to predict the preheating effect on workpiece and can be applied as a preheating temperature control method in laser assisted machining processes.展开更多
A finite element model was established for analyzing the geometric errors in turning operations and a two-step analyzing process was proposed. In the first analyzing step, the cutting force and the cutting heat for th...A finite element model was established for analyzing the geometric errors in turning operations and a two-step analyzing process was proposed. In the first analyzing step, the cutting force and the cutting heat for the cutting conditions were obtained using the AdvantEdge. Also, the deformation of a workpiece was estimated in the second step using the ANSYS. The deformation was analyzed for a 150 mm-long workpiece at three different measuring points, such as 10, 70 and 130 mm from a reference point, and the amounts of the deformation were compared through experiments. /n the results of the comparison and analysis, the values obtained from these comparison and analysis represent similar tendencies. Also, it is verified that their geometric errors increase with the increase in temperature. In addition, regarding the factors that affect the deformation of a workpiecc, it can be seen that the geometric error in the lathe is about 15%, the error caused by the cutting force is about 10%, and the deformation caused by the heat is about 75%.展开更多
To increase the machine accuracy by improving the stiffness of bearings,a preload was applied to bearings.A variable preload technology was necessary to perform machining processes in both low and high speed regions.A...To increase the machine accuracy by improving the stiffness of bearings,a preload was applied to bearings.A variable preload technology was necessary to perform machining processes in both low and high speed regions.An automatic variable preload device was fabricated using an eccentric mass.By installing the fabricated device on a spindle,the effect of the automatic variable preload device on the performance of the spindle was analyzed.In the results of the vibration measurement of the spindle,the vibration is increased by 20%-37% according to measurement points at the maximum rotation speed of 5 000 r/min.And,in the results of the noise measurement of the spindle,the spindle rotation speed is increased by about 1.9% and 1.5% at the front and side of the spindle,respectively.Based on the results of this analysis,an improved method that reduces such effects on the performance of the spindle is proposed.展开更多
Laser assisted turning （LAT） is one of the advanced machining technologies, which uses laser power to heat the surface of a workpiece before the material is removed. It has several advantages of low manufacturing co...Laser assisted turning （LAT） is one of the advanced machining technologies, which uses laser power to heat the surface of a workpiece before the material is removed. It has several advantages of low manufacturing costs, high productivity and high qualities to machine difficult-to-cut materials such as silicon nitride, muUite, zirconia and Ni. A large part of studies on LAT have been focused on a round bar. With increasing demands for high quality products and high performance engineering system, the researches on LAT for clover and square section members are necessary. But, these workpieces are impossible to be machined on conventional CNC lathe and to generate NC code with current CAM softwares. As a basic research for combining LAT with a tilting index table type 5-axis machining center, i.e. laser assisted turn-mill, a new method is suggested to generate NC code that can process various types of clover and square section members through development of C＋＋ program.展开更多
Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. Fi...Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. First of all, the thermal characteristic analysis was performed to verify the importance of laser module location. Laser module should be moved within 1 mm. Analysis conditions of three positions in driving range of the one-axis manipulator are selected. And a C coupling is used as a connection device for spindle and laser module. An initial model has one C coupling, and the number of C coupling has been increased from 1 to 2 in an improved model. And the analysis is carried out again for the one-axis manipulator. The results of the static analysis, the maximum displacement and the maximum stress are decreased by 22% and 11%, respectively, for the improved model when the laser module is located at farthest away from the spindle unit. As a result of the modal analysis, the first natural frequency mode is increased by 13%, 18% and 12% at these positions of the improved model, respectively. The harmonic analysis of the improved model was performed by analyzing the results of the modal analysis. The maximum deformation was 0.33 mm in driving unit at 222 Hz. And the maximum compliance of the ISO axis direction was 0.23 mm/N. Finally, the one-axis manipulator has been fabricated successfully using the analysis result.展开更多
The stability and reliability of a tilting index table should be considered at the design stage. A design method for the lightweight and improvement of the stability of the structure in a tilting index table was propo...The stability and reliability of a tilting index table should be considered at the design stage. A design method for the lightweight and improvement of the stability of the structure in a tilting index table was proposed using a commercial analysis program, ANSYS Workbench 12, by analyzing the static-thermal characteristics of the developed high-accuracy tilting index table at its design stage. The results of the performed structural analysis show that the maximum stress is generated at the stock tail part. An optimum design for the stock tail part was carried out to reduce the maximum stress and deformation. Also, the design variables were determined by considering the support of the stock tail part for the C-axis body. In the comparison of the results before and after the optimization, the maximum deformation and stress are improved by 2.8% and 8%, respectively.展开更多
基金Project(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE) of Korea
文摘Factors for determining the spindle size are the shaft diameter, positions of bearing and motor, and entire length of the spindle. Then, it is important to find the assembling of the optimal design variables, which satisfy the stiffimss and rotational speed required to the spindle. A general full factorial design method was used to verify some factors that affect the natural frequency of a spindle. It is verified that the shorter shaft length and bearing span length represent the higher natural frequency, and there are some effects according to the change in the levels of factors. The detailed spindle dimension is determined by applying an EVD method, which can define the optimal bearing position through considering the limiting condition. Based on the estimated regression model, the optimal spindle size and bearing distance that can improve the primary natural frequency are obtained, and the influence of design factors on the natural frequency is also analyzed.
基金Work(RTI04-01-03) supported by Grant from Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE),Korea
文摘To enhance machining efficiency,tool change time has to be reduced.Thus,for an automatic tool changer attached to a machining center,the tool change time is to be reduced.Also the automatic tool changer is a main part of the machining center as a driving source.The static attributes of the automatic tool changer using the commercial code,ANSYS Workbench V12,were tried to interpret.And the optimum design of automatic tool changer arm was proposed by performing the multi-stage optimum design.The shape optimization of the automatic tool changer was proposed and the result was verified to obtain acceptable improvements.It is possible to obtain an optimized model in which the maximum deformation,maximum stress,and mass are reduced by 10.46%,12.89% and 9.26%,respectively,compared with those of the initial model.Also,the results between conventional method by the design of experiments and proposed method by the multi-stage optimum design method were compared.
基金Project(70004782)supported by the Regional Strategic Technology Development Program of the Ministry of Knowledge Economy(MKE),KoreaProject(2011-0017407)supported by National Research Foundation(NRF)of KoreaWork financially supported by the Second Stage of Brain Korea 21 Projects
文摘Laser assisted machining （LAM） has difficulties in estimating temperature after applying a LAM process due to its very small heat input area, large energy and movement. In particular, in the case of laser assisted turning （LAT） process, it is more difficult to estimate the temperature after preheating because it has a shape of ellipse when a laser heat source is rotated. A prediction method and thermal analysis method for heat source shapes were proposed as a square shaped member was preheated. The temperature distribution was calculated according to the rotation of the member. Compared with the results of the former study, the maximum temperature of the calculation results, 1 407.1 ℃, is 8.5 ℃ higher than that of the square member, which is 1 398.6 ℃. In a LAT process for a square member, the maximum temperature is 1 850.8 ℃. It is recognized that a laser power control process is required because square members show a maximum temperature that exceeds a melting temperature at around a vertex of the member according to the rotation.
基金Project(RTI04-01-03) supported by the Regional Technology Innovation Program of Ministry of Knowledge Economy (MKE),Korea
文摘Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to obtain a positive motion from the follower using a rotating cam,its shape should be correctly designed and manufactured.The development of an adequate CAD/CAM system for a cam profile CNC grinding machine is necessary to manufacture high-precision cams.The purpose of this study is the development of a CAD/CAM system and profile measuring device for a CNC grinding machine to obtain an optimal grinding speed with a constant surface roughness.Three types of disk cams were manufactured using the proposed algorithm and procedures to verify effectiveness of the developed CAD/CAM system.
基金Project(2011-0017407)supported by the National Research Foundation of Korea(NRF)grant funded by the Korea government(MEST)
文摘For laser assisted machining,shape of preheating laser heat source is changed irregularly because of complexity of material shape.So,the preheating temperature should be controlled by adjusting the feed rate or the laser power.Thermal analyses of the laser assisted machining process for inclination planes were performed.By analyzing the obtained temperature profile,a proper feed rate control method was proposed according to the inclination angles.In addition,the temperature distribution of the cross section after feed rate control was predicted.The correlation equation between inclination angles and adjusted proper feed rate was proposed.The results of this analysis can be used to predict the preheating effect on workpiece and can be applied as a preheating temperature control method in laser assisted machining processes.
基金Project(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE),Korea
文摘A finite element model was established for analyzing the geometric errors in turning operations and a two-step analyzing process was proposed. In the first analyzing step, the cutting force and the cutting heat for the cutting conditions were obtained using the AdvantEdge. Also, the deformation of a workpiece was estimated in the second step using the ANSYS. The deformation was analyzed for a 150 mm-long workpiece at three different measuring points, such as 10, 70 and 130 mm from a reference point, and the amounts of the deformation were compared through experiments. /n the results of the comparison and analysis, the values obtained from these comparison and analysis represent similar tendencies. Also, it is verified that their geometric errors increase with the increase in temperature. In addition, regarding the factors that affect the deformation of a workpiecc, it can be seen that the geometric error in the lathe is about 15%, the error caused by the cutting force is about 10%, and the deformation caused by the heat is about 75%.
基金Project(2011-0027035) supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF)funded by the Ministry of Education,Science and Technology,Korea
文摘To increase the machine accuracy by improving the stiffness of bearings,a preload was applied to bearings.A variable preload technology was necessary to perform machining processes in both low and high speed regions.An automatic variable preload device was fabricated using an eccentric mass.By installing the fabricated device on a spindle,the effect of the automatic variable preload device on the performance of the spindle was analyzed.In the results of the vibration measurement of the spindle,the vibration is increased by 20%-37% according to measurement points at the maximum rotation speed of 5 000 r/min.And,in the results of the noise measurement of the spindle,the spindle rotation speed is increased by about 1.9% and 1.5% at the front and side of the spindle,respectively.Based on the results of this analysis,an improved method that reduces such effects on the performance of the spindle is proposed.
基金Project(2011-0017407)supported by the National Research Foundation of Korea(NRF)funded by Korea government(MEST)
文摘Laser assisted turning （LAT） is one of the advanced machining technologies, which uses laser power to heat the surface of a workpiece before the material is removed. It has several advantages of low manufacturing costs, high productivity and high qualities to machine difficult-to-cut materials such as silicon nitride, muUite, zirconia and Ni. A large part of studies on LAT have been focused on a round bar. With increasing demands for high quality products and high performance engineering system, the researches on LAT for clover and square section members are necessary. But, these workpieces are impossible to be machined on conventional CNC lathe and to generate NC code with current CAM softwares. As a basic research for combining LAT with a tilting index table type 5-axis machining center, i.e. laser assisted turn-mill, a new method is suggested to generate NC code that can process various types of clover and square section members through development of C＋＋ program.
基金Project(2012-0005688) supported by the National Research Foundation of Korea (NRF) Grant funded by the Korea Government (MEST)
文摘Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. First of all, the thermal characteristic analysis was performed to verify the importance of laser module location. Laser module should be moved within 1 mm. Analysis conditions of three positions in driving range of the one-axis manipulator are selected. And a C coupling is used as a connection device for spindle and laser module. An initial model has one C coupling, and the number of C coupling has been increased from 1 to 2 in an improved model. And the analysis is carried out again for the one-axis manipulator. The results of the static analysis, the maximum displacement and the maximum stress are decreased by 22% and 11%, respectively, for the improved model when the laser module is located at farthest away from the spindle unit. As a result of the modal analysis, the first natural frequency mode is increased by 13%, 18% and 12% at these positions of the improved model, respectively. The harmonic analysis of the improved model was performed by analyzing the results of the modal analysis. The maximum deformation was 0.33 mm in driving unit at 222 Hz. And the maximum compliance of the ISO axis direction was 0.23 mm/N. Finally, the one-axis manipulator has been fabricated successfully using the analysis result.
基金Project(70004782) supported by the Regional Strategic Technology Development Program of the Ministry of Knowledge Economy(MKE) of KoreaProject(2011-0017407) supported by the National Research Foundation of Korea (NRF) Funded by the Korea Government (MEST)
文摘The stability and reliability of a tilting index table should be considered at the design stage. A design method for the lightweight and improvement of the stability of the structure in a tilting index table was proposed using a commercial analysis program, ANSYS Workbench 12, by analyzing the static-thermal characteristics of the developed high-accuracy tilting index table at its design stage. The results of the performed structural analysis show that the maximum stress is generated at the stock tail part. An optimum design for the stock tail part was carried out to reduce the maximum stress and deformation. Also, the design variables were determined by considering the support of the stock tail part for the C-axis body. In the comparison of the results before and after the optimization, the maximum deformation and stress are improved by 2.8% and 8%, respectively.
