scholarly journals Observation of Drilling Burr and Finding out the Condition for Minimum Burr Formation

2014 ◽  
Vol 2014 ◽  
pp. 1-12 ◽  
Author(s):  
Nripen Mondal ◽  
Biswajit Sing Sardar ◽  
Ranendra Nath Halder ◽  
Santanu Das
Keyword(s):  
Experimental Results ◽  
Cutting Fluid ◽  
Burr Formation ◽  
Low Alloy Steel ◽  
Small Deviations ◽  
Burr Height ◽  
Machining Conditions ◽  
Dry And Wet Conditions ◽  
Exit Edge ◽  
Twist Drills

Suppression or elimination of burr formation at the exit edge of the workpiece during drilling is essential to make quality products. In this work, low alloy steel specimens have been drilled to observe burr height under different machining conditions. Taper shank, uncoated 14 mm diameter HSS twist drills are used in these experiments. Dry environment is maintained in experiment set I. Water is applied as cutting fluid in experiment set II. In the next four sets of experiments, the effect of providing back-up support material and exit edge bevel is observed on formation of burr at the exit edge of specimens under dry and wet conditions. It is revealed that an exit edge bevel of 31 degrees with water as the cutting fluid gives negligible burr at the exit edge of the drilled hole at certain machining conditions. Use of a back-up support can also reduce drill burr to a large extent. In this paper, artificial neural networks (ANN) are developed for modeling experimental results, and modeled values show close matching with the experimental results with small deviations.

An investigation on formation of burrs during milling of aluminium alloy under wet condition

2020 ◽  
pp. 095440542097201
Author(s):  
Raj Sekhar Mandal ◽  
Santanu Das ◽  
Partha Pratim Saha
Keyword(s):  
Suitable Condition ◽  
Face Milling ◽  
Machining Process ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Burr Height ◽  
Cutting Velocity ◽  
Wet Condition ◽  
Exit Edge ◽  
Coated Carbide

Undesirable burrs are created out of a machining process. The objective of the present work is to explore the suitable condition to obtain no burr, or negligible burr, around the edge of a machined product at wet condition. Face milling experiments have been carried out on blocks made of aluminum alloy (Alloy-4600M) with a single, coated-carbide inserted cutter for observing the nature of burr formation. Depth of cut has been maintained constant at 3 mm for all sets of experiments. In each experiment set, three cutting velocities (170 m/min, 237 m/min and 339 m/min) and three in-plane exit angles of 30°, 60° and 90° are provided at three different feeds of 0.08 mm/tooth, 0.1 mm/tooth and 0.12 mm/tooth. First set of experiments are done without any exit edge bevel. Similar sets of experiments are carried out with 15° and 30° exit edge bevel angles to find out the condition for minimum burr. The bevel is made of a height of 3 mm. In the present experimental investigation, a minimum burr height of as low as 3 micron is obtained at an in-plane exit angle of 30° and exit edge bevel angle of 15° under the machining condition of 339 m/min cutting velocity and 0.1 mm/tooth feed.

Surface Textured Drill Tools—An Effective Approach for Minimizing Chip Evacuation Force and Burr Formation During High Aspect Ratio Machining of Titanium Alloy

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
S. Niketh ◽  
G. L. Samuel
Keyword(s):  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Sliding Friction ◽  
Thrust Force ◽  
Research Work ◽  
Machining Process ◽  
Cutting Fluid ◽  
Burr Formation ◽  
Burr Height ◽  
Drill Tool

Abstract The real challenge pertaining to high aspect ratio drilling is the rapid increase in chip evacuation force due to the chip clogging phenomenon occurring at higher drilling depths. The clogged chips will further impede the reachability of cutting fluid at the machining zone leading to the tool temperature buildup. This will eventually result in the catastrophic failure of the tool. Hence, in the present work, an attempt has been made to minimize the chip evacuation force by functionalizing the drill tool surfaces based on the laser microtexturing principle. Microscale textures in the form of circular dimples were created on the flute and margin side of the drill tool with an objective to control the sliding friction, thereby minimizing the chip clogging effect. The effectiveness of the functionalized drill tools were assessed mainly based on the variation in thrust force and torque. Drilling experiments showed a net reduction of 17.18% in thrust force and 26.98% in torque while machining Ti–6Al–4V using the flute and margin textured tool, which justified the effectiveness of micro scale textures in minimizing the chip evacuation forces. The experimental analysis was further extended in terms of burr height evaluation, where FMT tools were found to be highly effective in burr height reduction (1.29 mm), showing a net reduction of 54.26% when compared with the non-textured tool. The outcomes from this research work will be highly beneficial for the manufacturing industries including aerospace, automobile, and spacecraft as high aspect ratio drilling of titanium alloys are still categorized to be the most challenging machining process owing to its lower thermal conductive property.

Burr Size Minimization When Drilling 6061-T6 Aluminum Alloy

2012 ◽  
Author(s):  
Y. Zedan ◽  
S. A. Niknam ◽  
A. Djebara ◽  
V. Songmene
Keyword(s):  
Process Parameters ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Cutting Fluid ◽  
Burr Formation ◽  
Formation Mechanisms ◽  
Regression Equations ◽  
Taguchi Optimization ◽  
Burr Height ◽  
Burr Size

The burr formation mechanisms strongly depend on the machining methods as well as cutting conditions. Cutting fluids play significant roles in machining, including reduction of friction and temperature. Using a cutting fluid, however, degrades the quality of the environment and increases machining costs. In the present work, initially the effects of cutting fluid application (dry, mist and flood) and their interaction with cutting parameters on the burr size during drilling of 6061-T6 aluminum alloys were investigated using multi-level full factorial design. Second-order non-linear mathematical models were developed to predict burr height for various lubrication modes. The accuracy of the regression equations formulated to predict burr height when using different lubrication modes has been verified through carrying out random experiments in the range of variation of these variables. A procedure was developed to minimize burr size for drilling holes by presenting the optimal levels of process parameters. Taguchi optimization method based on L9 orthogonal array design of experiment was then used which has shown very accurate process parameters selection that leads to minimum burr height. According to experimental study, it was observed that dry and mist drilling can produce parts with quality comparable with those obtained in wet drilling when using the optimal cutting conditions. In addition, increase in cutting speed and feed rate exhibits a decrease in burr size.

scholarly journals Cutting-fluid flow with chip evacuation during deep-hole drilling with twist drills

2021 ◽  
Author(s):  
Andreas Baumann ◽  
Ekrem Oezkaya ◽  
Dirk Schnabel ◽  
Dirk Biermann ◽  
Peter Eberhard
Keyword(s):  
Fluid Flow ◽  
Cutting Fluid ◽  
Hole Drilling ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Twist Drills

Prediction of Burr Formation in Fabricating MEMS Components by Micro End Milling

2009 ◽  
Vol 74 ◽  
pp. 247-250 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Mohd Aliff Omar ◽  
Khairul Irman Othman ◽  
Wayne N.P. Hung
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Burr Formation ◽  
Aisi 304 ◽  
Burr Height ◽  
Milling Parameters ◽  
Milling Tool ◽  
Micro End Milling ◽  
Chip Load

This paper discusses burr formation in micromilling of AISI 304 stainless steel. Chip load, cutting speed and the application of coolant were chosen as the milling parameters. Experiments were conducted using 500 µm diameter tungsten carbide end milling tool. Milling parameters and measured burr height values were analyzed and statistical models were developed for the estimation of burr height. The models showed that the chip load and cutting speed both have direct and interactive contribution to burr formation. When micromachining without coolant, the burr height increases about 40% compared to that of machining with coolant. The optimized values of chip load and cutting speed were found to be 1 µm/tooth and 78 mms-1 respectively. The predicted burr heights were 5-7% larger than that of measured values.

scholarly journals Finite Element Analysis and Statistical Optimization of End-Burr in Turning AA2024

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 276 ◽  
Author(s):  
Muhammad Asad ◽  
Hassan Ijaz ◽  
Waqas Saleem ◽  
Abdullah Mahfouz ◽  
Zeshan Ahmad ◽  
...  
Keyword(s):  
Finite Element ◽  
Orthogonal Cutting ◽  
Research Work ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Zones ◽  
Statistical Analyses ◽  
Burr Formation ◽  
Pivot Point ◽  
Exit Edge

This contribution presents three-dimensional turning operation simulations exploiting the capabilities of finite element (FE) based software Abaqus/Explicit. Coupled temperature-displacement simulations for orthogonal cutting on an aerospace grade aluminum alloy AA2024-T351 with the conceived numerical model have been performed. Numerically computed results of cutting forces have been substantiated with the experimental data. Research work aims to contribute in comprehension of the end-burr formation process in orthogonal cutting. Multi-physical phenomena like crack propagation, evolution of shear zones (positive and negative), pivot-point appearance, thermal softening, etc., effecting burr formation for varying cutting parameters have been highlighted. Additionally, quantitative predictions of end burr lengths with foot type chip formation on the exit edge of the machined workpiece for various cutting parameters including cutting speed, feed rate, and tool rake angles have been made. Onwards, to investigate the influence of each cutting parameter on burr lengths and to find optimum values of cutting parameters statistical analyses using Taguchi’s design of experiment (DOE) technique and response surface methodology (RSM) have been performed. Investigations show that feed has a major impact, while cutting speed has the least impact in burr formation. Furthermore, it has been found that the early appearance of the pivot-point on the exit edge of the workpiece surface results in larger end-burr lengths. Results of statistical analyses have been successfully correlated with experimental findings in published literature.

Mathematical Modeling of Electrochemical Deburring

2010 ◽  
Vol 126-128 ◽  
pp. 545-550 ◽  
Author(s):  
Wen Ji Xu ◽  
W. Wang ◽  
Xu Yue Wang ◽  
Gui Bing Pang
Keyword(s):  
Mathematical Modeling ◽  
Mathematical Model ◽  
Influencing Factors ◽  
Applied Voltage ◽  
Experimental Results ◽  
Electrode Gap ◽  
Workpiece Material ◽  
Burr Height ◽  
Object A ◽  
The Mathematical Model

The drilling burr is taken as the research object. A mathematical model of electrochemical deburring (ECD) is established and the effects of main influencing factors, such as inter-electrode gap, applied voltage and deburring time, on burr height have been analyzed. The results show that the deburring time increases with the increase of initial burr height, inter-electrode gap, with the decrease of volume of electrochemical equivalent of the workpiece material, conductivity of electrolyte and applied voltage. The deburring time for various burr heights can be predicted by the mathematical model. The calculated results obtained from the mathematical model are approximately consistent with the experimental results. The results show that initial burr height h0=0.722mm is removed, and the fillet radius R=0.211mm is obtained.

Investigation of Ultrasonic-Assisted Drilling of Al/SiC Metal Matrix Composite with Taguchi Method

2012 ◽  
Vol 523-524 ◽  
pp. 215-219 ◽  
Author(s):  
Mohammad Ali Kadivar ◽  
Javad Akbari ◽  
Reza Yousefi
Keyword(s):  
Taguchi Method ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Burr Formation ◽  
Burr Height ◽  
Burr Size ◽  
Ultrasonic Assisted ◽  
Drilling Parameter ◽  
Sic Particle

Burr in drilling plays an important role on product quality, so analysis the burr size is essential at the final production. This paper presents the application of Taguchi method for survey the burr height and burr thickness by adding ultrasonic vibration to the process. In this paper L18 orthogonal array based on Taguchi techniques was used in the design of experiments. Analysis of Variance (ANOVA) was used to determination the effect of drilling parameter on burr formation. Influence of cutting speed, feed rate and percentage of SiC particle was investigated in with and without Ultrasonic assisted drilling. Al/SiCp MMC with 5, 15 and 20 wt% of particulate SiC in dry drilling operation with TiN coated drill tools were investigated.

Study on Drilling of Al/Al2O3/Gr Hybrid Particulate Composites

2015 ◽  
Vol 766-767 ◽  
pp. 852-857 ◽  
Author(s):  
A. Saravana Kumar ◽  
P. Sasikumar ◽  
N. Nilavusri
Keyword(s):  
Experimental Investigation ◽  
Taguchi Method ◽  
Alumina Particle ◽  
Hybrid Composites ◽  
Cutting Speed ◽  
Particulate Composites ◽  
Exit Hole ◽  
Burr Height ◽  
Solid Carbide ◽  
Twist Drills

This study presents an experimental investigation on the effects of cutting speed, feed and percentage of alumina particle on the burr height in drilling of Al 6063 reinforced with Al2O3 and Gr particles using solid carbide twist drills of 6 mm diameter. Taguchi method with three factors at three levels is employed to analyze the drilling characteristics of these composites. For all cutting conditions, Al 6063/6%Al2O3/1%Gr composite has lower burr height values than other fabricated composites. The results revealed that exit hole burr height are greatly influenced by the feed rate rather than the speed for all the samples of hybrid composites.

Burr formation during drilling of mild steel at different machining conditions

2019 ◽  
Vol 34 (7) ◽  
pp. 726-735 ◽  
Author(s):  
A. Pramanik ◽  
A. K. Basak ◽  
M. S. Uddin ◽  
S. Shankar ◽  
S. Debnath ◽  
...  
Keyword(s):  
Mild Steel ◽  
Burr Formation ◽  
Machining Conditions
Sign in / Sign up

Export Citation Format

Share Document