표제지
목차
I. 서론 10
II. 이론적 배경 12
2.1. 가공변형의 일반사항 12
2.2. 고속가공의 정의 및 필요성 13
2.3. 가공변형에 대한 가설 14
2.3.1. 형태에 의한 변형 14
2.3.2. 가공에 의한 변형 16
III. 실험장치 및 방법 20
3.1. 절삭공구 실험 방법 20
3.1.1. 엔드밀 종류별 가공 실험 20
3.1.2. 고속가공 실험 장비 사양 21
3.2. 절삭공구 실험 결과 22
IV. 실험결과 및 고찰 27
4.1. 항공기 Wing Rib 28
4.2. 기존 중·저속 가공 32
4.2.1. 가공공정순서 32
4.2.2. 중·저속 가공의 단점 36
4.3. 고속가공 37
4.3.1. 1차 고속가공 37
4.3.2. 2차 고속가공 59
4.3.3. 3차 고속가공 65
V. 결론 72
참고문헌 73
Abstract 76
Table 2.1. Type and Characteristics of Al Alloy 15
Table 4.1. Specification of Wing Rib 28
Table 4.2. Permissible Amount of Self Weight 31
Table 4.3. Cutting Condition of Rough Cutting 39
Table 4.4. Cutter List of Finishing 40
Table 4.5. The 1st Test Process of High Speed Machining 43
Table 4.6. The 1st Test Self Weight of High Speed Machining 55
Table 4.7. The 1st Test 15kg x 4 Weight of High Speed Machining 57
Table 4.8. The 1st Test Final Deformation Results of High Speed Machining 58
Table 4.9. The 2nd Test Process of High Speed Machining 59
Table 4.10. The 2nd Test Self Weight of High Speed Machining 61
Table 4.11. The 2nd Test 15kg x 4 Weight of High Speed Machining 63
Table 4.12. The 2nd Test Final Deformation Results of High Speed Machining 64
Table 4.13. The 3rd Test Process of High Speed Machining 65
Table 4.14. The 3rd Test Self Weight of High Speed Machining 68
Table 4.15. The 3rd Test 15kg x 4 Weight of High Speed Machining 70
Table 4.16. The 3rd Test Final Deformation Results of High Speed Machining 71
Fig. 2.1. Types of Machining deformation 12
Fig. 2.2. Results of Machining in the Grain Direction 15
Fig. 2.3. Remove Stock 17
Fig. 2.4. Finishing Allowance of Sides & Bottom 19
Fig. 3.1. Primary Specification of High Speed Machine Center 21
Fig. 3.2. Correlation between N(rpm) and F(Feedrate) 22
Fig. 3.3. Width and Depth of cut 23
Fig. 3.4. Correlation between Section Area and Feedrate 23
Fig. 3.5. φ20-R5-Fillet-E/M test results(이미지참조) 24
Fig. 3.6. Vibration analysis(Spindle) test results 25
Fig. 3.7. Test results of optimal cutting conditions per Endmills 26
Fig. 4.1. Wing Rib 27
Fig. 4.2. Single Side Configuration of Wing Rib 29
Fig. 4.3. 15kg x 4 Weight → 0.5mm Max. permissible 29
Fig. 4.4. Gap Check Point 30
Fig. 4.5. Free condition tolerance → 5mm max. permissible 30
Fig. 4.6. Process sequence of Medium and Low speed Machining 32
Fig. 4.7. Pocket Rough cut Set-up & Cutter List 33
Fig. 4.8. Datum cut Set-up & Cutter List 34
Fig. 4.9. Pocket Finish cut Set-up & Cutter List 35
Fig. 4.10. Whether or not 0.5mm max. permissible amount is met when the load 15kg is applied to the 4 places each 36
Fig. 4.11. Process of High speed Machining 37
Fig. 4.12. Machining method improvement of Rough cutting process 38
Fig. 4.13. Machining datum surface using Face Cutter 39
Fig. 4.14. Tool holder by heat and heat supply equimpent for holder 41
Fig. 4.15. Configuration comparison between High and Normal speed E/M 42
Fig. 4.16. Interrelation of a Helix Angle 42
Fig. 4.17. Datum surface Cutting, T/H and M16 Bolt hole Machining 44
Fig. 4.18. Rough Cutting Cutter List 45
Fig. 4.19. φ32-R3.0-Tip-E/M(이미지참조) 45
Fig. 4.20. Material Set-up and shape after Machining 46
Fig. 4.21. S/V(Spindle Vibration) 47
Fig. 4.22. Deformation amount after Rough cutting 48
Fig. 4.23. φ160 Face Cutter Datum Facing(이미지참조) 49
Fig. 4.24. Datum Facing 49
Fig. 4.25. Set-up and shape after Machining 50
Fig. 4.26. Finishing Cutter List 51
Fig. 4.27. Finishing EndMills 51
Fig. 4.28. Set-up and shape after Machining 52
Fig. 4.29. Vacuum ON & OFF 53
Fig. 4.30. The 1st Test Self Weight of High Speed Machining 54
Fig. 4.31. The 1st Test 15kg x 4 Weight of High Speed Machining 56
Fig. 4.32. The 1st Test Final Deformation Results of High Speed Machining 58
Fig. 4.33. The 2nd Test Self Weight of High Speed Machining 60
Fig. 4.34. The 2nd Test 15kg x 4 Weight of High Speed Machining 62
Fig. 4.35. The 2nd Test Final Deformation Results of High Speed Machining 64
Fig. 4.36. The 3rd Test Self Weight of High Speed Machining 67
Fig. 4.37. The 3rd Test 15kg x 4 Weight of High Speed Machining 69
Fig. 4.38. The 3rd Test Final Deformation Results of High Speed Machining 71