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PCBN 공구를 활용한 마이크로 레이저 예열 엔드밀링 가공 연구
전용호(Yongho Jeon),Frank Pfefferkorn 한국생산제조학회 2011 한국생산제조시스템학회 학술발표대회 논문집 Vol.2011 No.4
본 연구는 PCBN 팁으로 특별 제작된 엔드밀을 사용하여 완전 소결 된 질화 규소의 마이크로 레이저 예열 엔드밀링 공법에 대한 타당성 검증을 목적으로 진행하였다. 기존 초경 공구를 사용하여 가공이 불가 했던 재료를 레이저 국소적 가열과 PCBN 팁을 공구를 활용하여 성공적으로 가공 할 수 있었으나, 과도한 가공 분력과, 가공 시 발생하는 고온으로 인하여 공구가 빠르게 파손되었다. 하지만, 본 연구를 통해 확인된 국소적인 소성 변형의 증거를 통해 난삭재로 알려진 완전 소결된 질화 규소의 가공이 가능하다고 판단된다.
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Marcus A. Jackson,Dan J. Thoma,Frank E. Pfefferkorn 한국정밀공학회 2023 International Journal of Precision Engineering and Vol.10 No.3
The objective of this work was to assess the energy consumption of a novel remanufacturing method that utilizes mechanically-generated feedstock for directed energy deposition. Gas-atomization is the state-of-the-art production process for directed energy deposition feedstock, and for this work was incorporated into a remanufacturing process path to provide a comparison method. Specific energy consumption models of remanufacturing utilizing both of these proposed process paths were developed and applied to a case study to investigate energy saving opportunities for future manufacturing paradigms. The energy modelling was done in three stages. First, the mechanically-generated feedstock production energy consumption model was generated from experimental observation. Second, the gas-atomized feedstock production energy consumption model was generated from a combination of experimental observation, reported estimates from the manufacturer, and data found in the literature. Lastly, the energy consumption model of directed energy deposition was derived from experimental observation and compares favorably with reported estimates in the literature. With the models, the specific energy consumption in the two process paths were compared and their application was demonstrated by estimating the energy consumption to remanufacture a bracket. The two feedstock production methods had similar specific energy consumptions. The specific energy consumption of the directed energy deposition process was the greatest component in the respective remanufacturing paths by an order of magnitude; increasing deposition rate is the most important factor for lowering the overall specific energy consumption. The analyzed remanufacturing technologies were estimated to consume less energy than replacement when repairing up to approximately 15% of the original part’s mass.
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Energy Consumption Model for Additive-Subtractive Manufacturing Processes with Case Study
Marcus A. Jackson,Arik Van Asten,Justin D. Morrow,Sangkee Min,Frank E. Pfefferkorn 한국정밀공학회 2018 International Journal of Precision Engineering and Vol.5 No.4
There has been a growing trend in industry towards the development of integrated manufacturing centers that combine several manufacturing processes, such as the mill-turn center. As additive manufacturing becomes a more widely adopted technology, combining additive with subtractive manufacturing in one machine is a logical evolution to provide the benefits of final parts made from raw materials with the dimensional tolerance and surface finish expected in many applications. An energy consumption model was created that accounted for the energy consumption during primary metal production, deposition, and machining phases of wire-based and powder-based additive-subtractive manufacturing processes. This model was applied to a case study where the energy consumption to produce sub-sized, sheet type, and plate type (size) tensile bars was calculated. It was found that the wire-based process consumed less energy during deposition, whereas powder-based was less energy consumptive during primary metal production and machining. The findings suggest that given the present understanding of the respective technologies’ capabilities, the desired final net shape will dictate the preferred manufacturing process with respect to energy consumption considerations.
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