Micro tool fabrication is crucial in micro machining. Wire electro-discharge grinding (WEDG) is one of the popular methods applied to fabricate micro tools used for micro electrical discharge machining (EDM), electrochemical machining (ECM), and ultrasonic machining (USM). WEDG can machine micro tools or features regardless of workpiece hardness. In WEDG, however, the machining speed is relatively low and the discharge gap control is not easy. In this study, the micro mechanical machining using the polycrystalline diamond is introduced to fabricate the micro cylindrical tool or micro pin of the tungsten carbide. This method demonstrates the possibility of applying ductile machining of tungsten carbide without brittle fracture or cracks. This paper compared the machining characteristics such as material removal rate and surface roughness with the PCD-mechanical machining and WEDG.
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With the development of 3D printing technology, its applications are expanding. However, 3D printed parts present a challenge in achieving high-quality surface roughness because of stair stepping problems. With the recent application of 3D printing in electronics and the visibility of flow in microfluidic systems, high-quality surface roughness is needed. Chemical mechanical polishing (CMP), one of semiconductor fabrication processes, has the longest planarization length in terms of productivity among existing planarization methods. In this study, we investigate friction characteristics of polishing of ABSLike resin material printed by the Stereolithography Apparatus (SLA). At the polishing of ABS-Like resin, the friction force has a high value at the beginning of polishing, but it stabilizes as processing progresses because of the effect of waviness on the printed material. The surface roughness (Sa and Sz) reduction and the glossiness of ABS-Like resins after polishing appear to be related to the reduction of the Shore D hardness resulting from the rise in the polishing process temperature caused by friction during polishing.
The cutting force signal has traditionally served as a reference in conducting the monitoring studies using a variety of sensors to identify the cutting phenomena. There have been continuing studies on how to monitor the cutting force indirectly. It is because it is easier to access when considering an application to the actual machining site. This paper discusses a method of indirectly monitoring the cutting force using the feed drive current to analyze the change in the trend of the cutting force over the lapse of machining time. This enables the analysis of the cutting force by separating it in the X and Y axes of the machining plane. To increase the discrimination of the signal related to the actual cutting phenomenon from the feed drive current signal, a bandpass filter was applied based on the tooth passing frequency. The relationship between the feed drive current and the cutting force analyzed from the machining signal of actual machining conditions was applied to convert the feed drive current into the cutting force. It has been verified through experiments that the cutting load can be estimated with markedly high accuracy as a physical quantity of force from the feed motor current.
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Tool Wear Monitoring System based on Real-Time Cutting Coefficient Identification Young Jae Choi, Ki Hyeong Song, Jae Hyeok Kim, Gu Seon Kang Journal of the Korean Society for Precision Engineering.2022; 39(12): 891. CrossRef
Recently, carbon fiber-reinforced plastic (CFRP) has been attracting much attention in various industries because of its beneficial properties such as excellent strength, modulus per unit density, and anti-corrosion properties. However, there are several issues in its application to various fields. Severe tool wear issues in its machining have been noted as one of the most serious problems because it induces various serious machining failures such as delamination and splintering. In this regard, timely tool replacement is essential for reducing the influence of tool wear. In this study, tool wear, especially flank wear, in the CFRP drilling was investigated and monitored. First, the reproducibility of tool wear under the same machining condition was experimentally evaluated. And it is demonstrated that tool wear may remarkably differ even though the same machining condition is applied to the tools. Then, tool wear monitoring based on the feed motor torque was applied to the detection of tool life ending in the CFRP drilling process. Consequently, it was demonstrated that the average and maximum detection error of the tool life end were less than 7 and 14%, respectively.
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Recently, interest in astronomy has increased internationally, and the technological development of lenses for large space telescopes is progressing. The multi-order diffractive engineered (MODE) lenses can make a large space telescope light and thin. However, because glass lenses are difficult to machine, we have adopted a method of molding at high temperature and high pressure. The STAVAX is commercially available chrome alloy stainless steel, and it is applied as various mold materials. The ultrasonic vibration cutting was adopted for ultra-precision machining because the tool wear is severe when cutting the STAVAX with a diamond tool. To achieve a flat surface for smooth ultrasonic vibration cutting, we performed a precise shape cutting using a CBN tool and confirmed and observed changes in the surface roughness and hardness depending on the cutting conditions. The ultrasonic vibration cutting was performed on the surface of the machine using a CBN tool, and the surface roughness was observed. It was confirmed that the surface roughness was impacted by the surface hardness. The specimens with low surface hardness showed the highest surface roughness at approximately 3 nm.
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There are many nonlinear vibration problems of mechanical structures because of various reasons such as geometric parameters, impact loads, or property of materials. One simple solution for the suppression of nonlinear structural vibration is input shaping that generates a command signal to cancel its vibration. However, a motion platform to evaluate the performance of input shapers for nonlinear vibration is rare. This paper presents the evaluation of input shaping methods for the nonlinear vibration system using a Furuta pendulum. First, the mathematical model of the Furuta pendulum is introduced and its nonlinear vibration characteristic is analyzed. Then, commands for canceling the nonlinear vibration of the Furuta pendulum are generated with various input shapers such as ZV, ZVD, and ZVDD. Finally, we illustrate the effects of input shapers on the nonlinear Furuta pendulum by comparing the pendulum overshoot, settling time, and vibration-reduction ratio. The Furuta pendulum is shown to be a good motion platform to evaluate input shaping methods for nonlinear vibration systems.
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Deep drawing is one of the most crucial processes in sheet metal forming. As for the multi-stage deep drawing process, because of many design parameters it comprises, predicting process results is a difficult and time-consuming task. In this study, to predict process results, the deep neural network was proposed. Seven design parameters were set and their range was determined with references to empirical formulas. Then, we determined prediction outputs, comprising maximum effective strain, minimum thickness, and bottom mean thickness. Five-hundred sampling points were determined using latinhypercube sampling method. According to the sampling points, finite element analysis was conducted to achieve process results. From the data rendered by the finite element analysis, the deep neural network was trained. Then, the deep neural network was tested with an additional 80 test samples to evaluate performance, and its performance was compared with radial basis function kernel support vector regression. The results showed that the relative performance of the deep neural network was superior to support vector regression.
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The munitions industry uses high-strength carbon fiber composites imported from other countries because of the lack of the information about the properties that should be satisfied by the domestic high-strength carbon fiber composites. Verification of the applicability of domestic high-strength carbon fiber composites to the munitions industry requires comparison of the fiber strength transition rate between the carbon fiber composites imported from other countries and domestically. A strand test was performed to evaluate in the unit of a fiber the mechanical properties of the imported high-strength carbon fiber composites and domestically. Additionally, a composite pressure vessel was prepared using the filament winding method to perform a hydrostatic pressure test and calculate the fiber strength in the unit of a structure. Comparison of the fiber strength results showed that the fiber strength transition rates of the domestic carbon fiber composites H2550 and H3055, were 86.35 and 74.19%, respectively. Domestic carbon fiber composite material H2550 is expected to be replaceable in the munitions industry.
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Lithium primary cells have the advantages of stable operating voltage, high energy density, long storage life, low discharge rate, and wide operating temperature range. Although not as reusable as lithium ion batteries, lithium primary batteries have been used in various fields, such as medical, environmental, and military, which require a small amount of current for a lengthy period or combined safety. In this study, MnO₂/CFx hybrid primary batteries comprising manganese dioxide and carbon fluoride (CFx), the main cathode materials of lithium primary battery, were fabricated and their discharge performance was measured. The discharge curve of the Li-MnO₂/CFx cells was classified into the MnO₂ phase and the CFx phase at low C-Rate. As the ratio of CFx increases, the discharge capacity of the battery increases, but the rate characteristics decreases. Considering all parameters such as capacity, rate capability, and temperature, the optimum amount of CFx doping was 70%. The mixing ratio of CFx/MnO₂ hybrid cathode can remarkably control the electrochemical performances and this kind of mixing ratio is expected to improve the electrochemical performances.
In this paper, we present a simple and robust fabrication method for mushroom-shaped microstructures using diverse polymers with various modulus of elasticity. Through the repeated replica molding process, we fabricated the same PDMS mushroom structure negative mold as the prepared silicon master mold. To evaluate the fabricating stability of the fabricated PDMS negative mold, the mushroom-shaped structures were replicated from the mold using six types of polymer resins with different elastic modulus and we measured superhydrophobic properties on the samples. All the fabricated samples exhibited superhydrophobicity, and we proved the structural stability of the proposed replication method through the measured SEM images, contact angles on the samples, and theoretical analysis based on the structural shape.
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