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.

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.

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.

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.

White and Dark Layer Analysis Using Response Surface Methodology

2012 ◽  
Vol 504-506 ◽  
pp. 1335-1340 ◽  
Author(s):  
Giuseppina Ambrogio ◽  
Serena di Renzo ◽  
Francesco Gagliardi ◽  
Domenico Umbrello
Keyword(s):  
Layer Thickness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Bearing Steel ◽  
Cutting Conditions ◽  
Cutting Fluid ◽  
Process Conditions ◽  
Dark Layer ◽  
Layer Analysis

This paper presents a study of the influence of cutting conditions on the finished surface obtained after an hard turning process, in particular a case study is presented where AISI 52100 bearing steel is machined under different cutting conditions. An analysis carried out using Surface Response Methodology has been developed in order to study the influence of the main cutting parameters such as cutting speed, feed rate and workpiece initial hardness on white (WL) and dark layer (DL) thickness. The whole experimental campaign has been performed using a chamfered PCBN tool inserts without any cutting fluid. Results show an evident influence of cutting speed and feed rate on both white and dark layer thickness while less relevant is the contribute given from the workpiece hardness on defining WL and DL depth. Finally, a model to find the optimal process conditions to minimize white and dark layer thickness is developed.

scholarly journals Post-Processing of FDM 3D-Printed Polylactic Acid Parts by Laser Beam Cutting

Polymers ◽  
2020 ◽  
Vol 12 (3) ◽  
pp. 550 ◽  
Author(s):  
Mahmoud Moradi ◽  
Mojtaba Karami Moghadam ◽  
Mahmoud Shamsborhan ◽  
Mahdi Bodaghi ◽  
Hamid Falavandi
Keyword(s):  
Process Parameters ◽  
Focal Plane ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Poly Lactic Acid ◽  
Regression Equations ◽  
Post Processing ◽  
Fused Deposition ◽  
3D Printed

In this paper, the post-processing of 3D-printed poly lactic acid (PLA) parts is investigated. Workpieces are manufactured by fused deposition modeling (FDM) 3D printing, while they may have defects in some areas such as edges. A post-processing is introduced here for 3D-printed samples by low power CO2 laser. The thickness of the FDM samples are 3.2 mm and printed by optimum conditions. Effects of process parameters such as focal plane position (−3.2–3.2 mm), laser power (20–40 W), and laser cutting speed (1–13 mm/s) are examined based on the design of experiments (DOE). Geometrical features of the kerf; top and bottom kerf; taper; ratio of top to the bottom kerf are considered as output responses. An analysis of the experimental results by statistical software is conducted to survey the effects of process parameters and to obtain regression equations. By optimizing of the laser cutting process; an appropriate kerf quality is obtained and also optimum input parameters are suggested. Experimental verification tests show a good agreement between empirical results and statistical predictions. The best optimum sample with 1.19 mm/s cutting speed, 36.49 W power and 0.53 mm focal plane position shows excellent physical features after the laser cutting process when 276.9 μm top and 261.5 μm bottom kerf width is cut by laser.

Effect of Process Parameters on Burrs Produced in Micromilling of a Thin Nitinol Foil

2013 ◽  
Vol 1 (2) ◽  
Author(s):  
George K. Mathai ◽  
Shreyes N. Melkote ◽  
David W. Rosen
Keyword(s):  
Process Parameters ◽  
Kinematic Model ◽  
Adhesive Bond ◽  
Burr Formation ◽  
Burr Height ◽  
Backing Material ◽  
Biomedical Device ◽  
Important Interaction ◽  
Thin Nickel ◽  
Device Applications

This paper examines the formation of burrs in micromilling of a thin nickel–titanium alloy (nitinol) foil used in implantable biomedical device applications. The paper analyzes the effects of key micromilling process parameters such as spindle speed, feed, tool wear, backing material, and adhesive used to attach the foil to the backing material on the burr height. It is found that burr height is larger on the downmilling side for grooves cut with a worn tool at high feeds, low spindle speeds with a softer backing material, and a weaker adhesive bond. Some important interaction effects of these factors are also studied. The study also shows that the mechanics of burr formation in such thin materials depends on whether the mode of cutting is dominated by tearing or chip formation, which is a function of the feed rate. A kinematic model to predict burr widths is developed and verified through experiments.

An Analytic Mechanistic Cutting Force Model for Milling Operations: A Case Study of Helical Milling Operation

1994 ◽  
Vol 116 (3) ◽  
pp. 331-339 ◽  
Author(s):  
A. E. Bayoumi ◽  
G. Yucesan ◽  
L. A. Kendall
Keyword(s):  
Process Parameters ◽  
Mechanistic Model ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Helical Milling ◽  
Force Model ◽  
Milling Operations ◽  
Milling Operation ◽  
Force Data

The milling force theory developed (Bayoumi et al., 1994) is applied to conventional helical milling operations. Force relationships for this case were obtained. The process parameters were treated as variables, and a methodology to compute them as a function of rotation angle from the sampled force data was developed. Experiments were carried out to test and/or refine the accuracy of the developed force model. The effect of cutting conditions such as radial and axial engagements and cutting speed on the process parameters was investigated. Some cutting tests were carried out using multiedges cutters at different cutting conditions and different tool and workpiece materials to verify the mechanistic model. The predicted results compared well with the experimental measurements.

scholarly journals Optimization of Performance Parameters in Drilling Process for Minimizing the Burr Formation

2018 ◽  
Vol 7 (2) ◽  
pp. 127-131
Author(s):  
Jatinder Singh ◽  
Kulvinder Garg
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Low Cost ◽  
Environmental Parameters ◽  
Burr Formation ◽  
Drilling Process ◽  
Burr Height ◽  
Optimization Of Process Parameters ◽  
Product Acceptability ◽  
The Cost

Presently a-days precision manufacturing has picked up its significance in all assembling industries. The best product dimensions at low cost with minimum time become a measure of concern. The drilling process imparts more than 30% of all the metal removing operations done on a job or assembly. The burr is a plastically deformed material, generated during drilling is unnecessary output and reduces the product acceptability, often lowers the surface quality of the product requires deburring which increases the cost of product. Burr is caused due to improper machining, tooling and environmental parameters. Total elimination of burrs during drilling process is a difficult task but using proper process parameters it can be minimized. In the present experimental study, the optimization of process parameters for minimization of burr formation in drilling process has been carried out for Al6082 plate. The tool type (coated/uncoated), spindle speed, feed rate, and drill diameters were used as the process parameters. Taguchi’s L18 orthogonal has been applied for DOE and drilling of Al6082 plates has been performed using ply-board as a backup support and without using any backup support on CNC drilling machine. The burr height and surface roughness were analyzed and optimized using S/N ratio and ANOVA and the optimum combinations for burr height and surface roughness has been found from S/N plots. The most influencing factors for burr height and surface roughness have been found from ANOVA tables.

Selection of dry drilling parameters for minimal burr size and desired drilling quality

2015 ◽  
Vol 231 (3) ◽  
pp. 480-489 ◽  
Author(s):  
Sona Azarrang ◽  
Hamid Baseri
Keyword(s):  
Removal Rate ◽  
Cutting Speed ◽  
Drilling Process ◽  
Inference System ◽  
Burr Height ◽  
Burr Size ◽  
Drilling Parameters ◽  
Input Parameters ◽  
Tool Diameter ◽  
Selection Of

The drilling of metals produces undesired raised material which is defined as burr. It is important to minimize the burr size by modifying the drill geometry or selection of drilling parameters. Although, selection of optimal drilling parameters can be minimize the burr size, but it may be increases the overcut or decreases the material removal rate (MRR). In this paper, drilling parameters have been selected for minimal burr size and desired overcut and MRR. Four adaptive neuro fuzzy inference system (ANFIS) models have been designed based on experimental observation in drilling of copper. Outputs of ANFIS models are burr height, burr thickness, burr type and overcut of hole; While input parameters of drilling process are cutting speed, tool diameter and ratio of feed rate to diameter. Then the particle swarm optimization method has been used to select the optimum condition of input parameters to minimize the burr size in desired value of overcut and MRR. Results showed that the proposed models can be predict the outputs well and they can be used as adequate predictors and optimizer for achieving the drilling parameters which gives a type of burr with low value of burr height and burr thickness with desirable overcut and MRR.

Study on Burr Formation in Face Milling of Stainless Steel with Chamfered Cutting Tool

2008 ◽  
Vol 53-54 ◽  
pp. 83-88 ◽  
Author(s):  
Lu Lu Jing ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Stainless Steel ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Face Milling ◽  
Cutting Edge ◽  
Burr Formation ◽  
Maximum Height ◽  
Machining Parameters ◽  
Burr Size ◽  
Exit Burr

Due to the properties such as high strength and high toughness, burr was commonly produced in the machining of stainless steel 1Cr18Ni9Ti, especially when a chamfered cutting tool was used. This study investigated the effects of chamfering geometry of cutting edge and machining parameters on burr formation and presented active control methods to minimize burr size on the exit end based on the experimental research in milling of 1Cr18Ni9Ti. Experiments of face milling with various cutting edge geometric features were conducted. Maximum height and thickness of exit burr and exit side burr were measured. As a result, a proper chamfering geometry that combined the advantages of enhancing the cutting edge strength and obtaining favorable burr types was presented. The experimental results also showed that a relatively high cutting speed was helpful in reducing burr formation; proper medium feed rate and axial depth were favorable for the minimization of burr size. This research is beneficial for precise machining of stainless steel.

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