Technology Assessment

on

Current Advanced Research Projects in Burr Formation and Deburring

AMT The Association for Manufacturing Technology January 2004

A Report Compiled and Prepared by

Sangkee Min, Ph.D. Postdoctoral Researcher The Laboratory for Manufacturing Automation Professor David A. Dornfeld, Ph.D. The Department of Mechanical Engineering The University of California at Berkeley Berkeley, California 94720-1740, U.S.A. http://lma.berkeley.edu
for

AMT The Association for Manufacturing Technology

Published by: AMT The Association for Manufacturing Technology 7901 Westpark Drive, McLean, VA 22102 Printed in the United States of America Copyright 2004 AMT The Association for Manufacturing Technology all rights reserved. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.

Index
Preface 1. Introduction 1.1. Definition of the burr 1.2. Burr geometry 1.3. Burr formation mechanism 1.4. Burr types 1 2 3 4 5 10

2. Burr metrology 2.1. Classification and standard 2.1.1. Classification of burrs in general machining x L. K. Gillespie x Yokohama National University, Japan 2.1.2. Classification of burrs in face milling 2.1.3. Classification of burrs in drilling 2.1.4. Survey of standards of burr and edge 2.2. Measurement system and sensor 2.2.1. Burr size measurement using a capacitance sensor 2.2.2. Burr size measurement using a laser displacement sensor 2.2.3. Measurement of drilling burr by image processing technique

13 13 13 13 14 16 18 20 21 21 22 23

3. Understanding of burr formation 3.1. Analytical modeling 3.1.1. Analytical modeling of burr formation in orthogonal cutting 3.1.2. Analytical modeling of edge breakout in orthogonal cutting 3.1.3. Analytical modeling of burr formation and fracture in oblique cutting 3.1.4. Analytical modeling of burr formation in milling 3.1.5. Analytical modeling of burr formation in drilling 3.1.6. Modeling of burr formation at various exit surface geometry in drilling 3.2. Empirical modeling 3.2.1. Exit failure in interrupted cutting 3.2.2. Effect of axial rake angle on burr formation in face milling 3.2.3. Effect of in-plane exit angle on burr formation and classification of burrs in face milling 3.2.4. Various burrs in square shoulder face milling 3.2.5. Burr formation in side-milling cutters 3.2.6. Burr formation in drilling small holes 3.2.7. Drilling burr formation in titanium alloy (Ti-6Al-4V) 3.2.8. Influence of workpiece exit angle on burr formation in drilling intersecting holes 3.2.9. Burr formation in drilling of intersecting hole with gun and twist drills 3.2.10. Statistical study of burr formation and hole quality in drilling

24 24 24 25 26 27 28 29 30 30 31

32 33 34 35 36 37 38 39

3.2.11. 3.2.12. 3.2.13. 3.2.14.

Relationships between hole quality and drilling forces Effect of process parameters on surface finish of drilled holes Entrance and exit burr formation in drilling and reaming Study on mechanism and similarity of burr formation in face milling and drilling 3.2.15. Formation and properties of burrs in various machining processes 3.3. Computer based modeling 3.3.1. Finite element modeling of burr formation in orthogonal cutting 3.3.2. Finite element analysis of the influences of exit angle and rake angle on burr formation in orthogonal cutting 3.3.3. Finite element modeling of burr formation in oblique cutting 3.3.4. Finite element analysis of mechanical state on sequentially machined surfaces 3.3.5. Finite element modeling of burr formation in drilling 3.3.6. Thrust force analysis of drilling burr formation using finite element method 3.4. Other approaches 3.4.1. Probabilistic prediction of burr formation of carbon steel (AISI 1045) in face milling 3.4.2. Prediction of burr size using neural networks and fuzzy logic in face milling 3.4.3. Drilling burr control charts for stainless steel (AISI 304L) and low alloy steel (AISI 4118)

40 41 42 43 44 45 45 47 48 50 51 53 54 54 55 56

4. Burr minimization and prevention 4.1. Process planning 4.1.1. Burr minimization in face milling by geometric approach 4.1.2. Multi-agent process planning for a networked machining service 4.1.3. Prediction and simulation of milling burr formation for edge-precision process planning 4.1.4. Geometric approaches for reducing burr formation in planar milling by avoiding tool exits 4.1.5. Tool path planning for exit burr minimization by estimating the total length of primary burrs 4.1.6. Avoiding tool exit in planar milling by adjusting width of cut 4.1.7. Burr minimization in face milling 4.1.8. Feature sequencing for burr minimization 4.1.9. Various methods to minimize the burr formation in milling and drilling 4.2. Tool development 4.2.1. Influence of approach angle on minimizing the burr size in metal cutting 4.2.2. Development of the drill attachment for drilling burr minimization 4.3. Alternative processes 4.3.1. Low frequency vibratory drilling for burr minimization 4.3.2. Burrless drilling by ultrasonic vibration

58 58 58 59 60 61 63 64 66 67 68

69 69 70 71 71 72

4.4. Expert systems 4.4.1. Architecture for integrated design and manufacturing for burr minimization of precision mechanical components 4.4.2. Burr expert systems for milling and drilling 4.5. Other approaches 4.5.1. Finite element analysis of burr minimization with a backup material in orthogonal cutting 4.5.2. Finite element analysis of burr minimization with a backup material in drilling 4.5.3. Product design strategy for burr prevention

73 73 74 75 75 76 77

5. Deburring 5.1. Mechanical deburring 5.1.1. Barrel tumbling x University of Nottingham x University of Stuttgart 5.1.2. Vibratory deburring 5.1.3. Recipro deburring 5.1.4. Flow finishing 5.1.5. Abrasive jet deburring x Indian Institute of Technology, Bombay x Lawrence Technological University 5.1.6. Automated deburring with a filamentary brush 5.1.7. Development of deburring machines for precision parts in mass production 5.1.8. Development of design rules for robot deburring 5.1.9. Intelligent deburring robot based on human demonstration 5.1.10. Ultrasonic deburring 5.2. Thermal deburring 5.2.1. Laser deburring x Hanyang University, Korea x University of California at Berkeley 5.2.2. Thermal energy deburring 5.3. Chemical deburring 5.3.1. Development of chemical solutions for ferrous alloys 5.3.2. Chemical accelerators 5.3.3. Thermochemical deburring 5.4. Electrical deburring 5.4.1. Electrochemical deburring 5.4.2. Rotolytic finishing 5.5. Other approaches 5.5.1. Burr prediction and cost function for deburring

78 80 80 80 81 82 83 84 85 85 86 87 88 89 90 91 92 92 92 93 94 95 95 96 97 98 98 99 100 100

5.5.2. 5.5.3. 5.5.4. 5.5.5.

Acoustic emission feedback for precision deburring Design of an efficient deburring tool path Strategies to minimize deburring costs Overview of deburring and edge finishing

101 102 103 104

6. Miscellaneous Area 6.1. Micro-burrs 6.1.1. Burr formation in micro-grooving of optical components 6.1.2. Burr formation in micro-machining of aluminum alloy (Al 6061-T6) 6.1.3. Burr formation in high speed micro-deep drilling 6.1.4. Removal of burr in micro-grooves 6.1.5. Measurement and effective deburring of micro-burrs in piercing operation 6.1.6. Molecular dynamics simulations of burr formation in nanometric cutting 6.2. Research technology 6.2.1. Integration of CAD model of the drill with FEA for drilling burr simulation 6.2.2. An analysis of the burrs in drilling precision miniature holes using Fractional Factorial Design References

105 105 105 106 107 108 109 110 112 112

113 114

Preface
This report was based on an extensive survey of printed literature and website information. We have used our best efforts to locate and access the most updated information on concurrent research projects worldwide in the area of burr formation, deburring and related finishing areas. We caution the reader that some contact information and/or the current status of some research projects may be outdated or incorrect. We also mention that a substantial portion of the information reviewed comes from our own work at Berkeley. In spite of the tremendous importance of this area, there are a limited number of research activities in this ongoing in the world. We have tried to include the widest possible base of information from all available sources in our review. There are a number of excellent general sources for some of this information identified in the body of the report. We have adopted a format for reporting on other specific projects used in other AMT Technology Assessment Reports. The authors would like to express their appreciation to the members and friends of the Consortium on Deburring and Edge Finishing (CODEF) at Berkeley whose information and financial support have made possible much of the information reported in this document. We acknowledge the helpful discussions over many years with our collaborators at Boeing (Paul Ffield), Daimler-Chrysler (Klaus Berger) and Ford Motor Company (Rich Furness and Tim Hull). In particular, the work of the following students is acknowledged as some information was drawn from their reports while students at Berkeley: Emanuel Chibesakunda, Ingo Essel, Christian Rosier, Boris Stirn, and Henning Storhaug. We also appreciate Shantanu Tripathi and Soyeon Kim for their great assistance. Finally, the authors appreciate the opportunity presented by AMT to prepare this work and we hope that it is useful.

Sangkee Min David Dornfeld Berkeley, January 23, 2004

1. Introduction
A burr is formed due to incompleteness of cutting mechanism during machining process in general. Machining is not necessarily only the process creating the burr but it is the most concerned process in the burr related industry and academia. All machining processes intend to process a raw or partially shaped workpiece material into a designed shape with a specific size and tolerance. A fundamental weakness in machining processes, that a cutting always requires a sustainable workpiece material, however, causes bending or break-off of the workpiece material. The result of the former is the burr and that of the latter is the edge break. Machining processes are most widely used in manufacturing industry. Therefore, the burr, an unintended outcome of machining processes, has been a widely recognized problem to the industry. It ruins the design integrity of the part, requires additional processes to fix it, causes safety hazards, and results in malfunction of the product. All these side effects represent unnecessary cost to the industry in various forms such as additional manufacturing, compensation, service, recall, and collateral damage on the company image. Therefore, in most cases, it is a must either to remove or to secure the burr in order to prevent it from being detached from the part. Traditionally, burr problems had been considered unavoidable so that most efforts had been made on removal of the burr as a post process. Naturally, many deburring processes have been developed and for their effectiveness and competitiveness, many research have been conducted. Nowadays, a trend of manufacturing is an integration of the whole production flow from design to final product. Manufacturing issues are handled in various stages even from design stage. Therefore, the methods of describing the burr are getting much attention in recent years for the systematic approach to resolve the burr problem at various manufacturing stages. Since the burr can be formed in many machining processes, its shape, size, and cause of formation have huge variety. Even for the same machining process, it can be totally differently viewed depending on the industry. Hence, definitions and described characteristics for the same burr are infinitely found. For the same reason, there is no internationally recognized definition or standard on the burr and its related terminologies. Fortunately, there has been an activity to create an international standard on the burr. And also, many research groups have proposed ways to define and classify the burr. Some of these efforts are summarized in chapter 2.

1.1 Definition of the burr

In order to help to understand several terminology used in this report, several definitions of the burr are introduced. Schfer [1] describes the burr as the part of a workpiece which is produced through manufacturing processes on an edge or a surface and which lies outside the desired geometry and Ko and Dornfeld [2] defined a burr as an undesirable projection of material formed as the result of plastic flow from a cutting or shearing operation. A similar definition of the burr among many can be found in the German standard DIN 6784 [1] by the Deutsches Institut fr Normung (DIN) that defines an edge with a burr, a sharp edge and a burr free edge. The burr is described as a workpiece edge with overhang, Figure 1.1. While Schfers definition includes burrs on surfaces, which are likely to be produced in casting or welding operations, the DIN definition is limited to workpiece edges only.

burr-free

sharp-edged

burr overhang

theoretical workpiece edge

Figure 1.1 Deutschens Institut fr Normung (DIN) definition of burrs [1]

One of the latest definitions regarding burrs was introduced by Gillespie in a draft for the World-wide Burr Technology Committee (WBTC) [4] which is a consortia of the following national associations: Burr, Edge and Surface Technology of China (BEST-C) Burr, Edge and Surface Technology of Japan (BEST-J) Burr, Edge and Surface Technology of Korea (BEST-K) Burr, Edge and Surface Technology of Russia (BEST-R) Burr, Edge and Surface Technology of USA (BEST-USA) Contrary to the German understanding of burrs, Gillespies definition of the burr is limited to cutting and shearing processes. A burr produced through those operations includes all the material extending past the theoretical intersection of two surfaces, which surround the burr. Because the reference in that case is the theoretical intersection of the two surfaces and not the desired surface, Gillespie states that burrs could also lie inside the theoretical intersection as shown in Figure 1.2.

burr

burr

theoretical workpiece edge burr

Figure 1.2 Examples of Gillespies burr definition [3]

1.2 Burr geometry

Characterization of the burr also depends on the application. In terms of deburring, how strongly the burr is attached to the workpiece material may be the most important. For safety concern, sharpness of the burr may be the most important. Most widely used characterization of the burr was proposed by Schfer [1]. He stated that every burr can be characterized by its longitudinal and cross sectional profile. The length profile shows the shape of the burr along the edge and the cross sectional profile describes the shape perpendicular to the edge. While the only geometrical size in the longitudinal section is burr length, the more important burr characteristics are defined in the cross sectional profile. The burr shape in this profile is described through burr height, burr thickness, burr root thickness and burr radius, Figure 1.3.

hf

bg

rf h hf bg rf = = = = burr height burr root thickness burr thickness burr radius

Figure 1.3 Burr Variables by Schfer [2]

The longitudinal profile of the burr is not very informative, and is rarely used to describe burrs. The length of the burr is of some interest only because it describes how much of the total edge length that has burrs, and this is directly related to the deburring time of the work piece. In other words it gives an estimate on how long time and then how much it will cost to deburr the part. Still it is most common to refer to parameters of the burr cross sectional profile when describing burrs. Link [5] proposed a measure called Gratwert using the quantities defined by Schfer. The Gratwert g gives a comparable sense of the deburring effort, which is defined as:

4 b f  2 rf  bg  h 8

Contrary to the description of the burr geometry above, the DIN-standard uses only one value to define the deviation from the ideal geometrical outline of the edge, Figure 1.4. The size of the edge area is termed edge measure a. This value is measured from the burr tip perpendicular to the work piece surface from which the burr is protruding.

Figure 1.4 Burr geometry defined by DIN [3].

1.3 Burr formation mechanism

For the sake of efficient deburring, burr minimization, or burr prevention, understanding of burr formation mechanism is the most important. Many research groups came up with many different models through experimental observation, analytical deduction, and computational simulation. Hashimura, Chang, and Dornfelds model [6] for orthogonal cutting and Min, Dornfeld, Kim, and Shyu [7]s model for drilling are briefly introduced here and the rest of these models is introduced in Chapter 3. Hashimura, Chang and Dornfeld developed a basic model of burr formation, including the influence of material properties, based on simulation and experimental tests. To contain all possibilities, they conducted FEM simulations, machining tests under both optical and scanning electron microscope, and they clarified the effect of the tool conditions, cutting conditions and material properties. However, the model is restricted to orthogonal cutting. The model is characterized by eight stages of burr formation, whereby the first five stages are identical for both ductile and brittle materials, Figure 1.5. Starting from a continuous cutting (1) process, the deformation and stress distribution has no effect on the burr formation as long as it is not affected by the workpiece edge. Then the pre-initiation (2) sets in. The elastic deformation zone either intersects the workpiece edge or appears at the workpiece edge as elastic bending, supported by the plastic deformation zone around the primary shear zone that also extends towards the workpiece edge. As the tool approaches, the elastic bending changes and appears as plastic bending at the workpiece edge. During this burr initiation (3) stage, the plastic deformation zone around the primary shear zone and the primary shear zone itself, extend. The pivoting (4) stage exhibits the phase where a pivoting point appears on the workpiece edge and a large deformation occurs, recognizable by decreasing cutting forces. The next stage is described by negative shearzone development (5), wherein the burr develops and the large deformation at the pivoting point expands to connect with the deformation in the primary shear zone. The more the tool approaches the workpiece edge, the more the workpiece corner pivots with the chip. This results in increased burr sizes.

The prior-mentioned burr-formation stages were indicated by deformation mechanisms. As soon as crack initiates, it is useful to distinguish between the further development of burr formation by ductile (d) and brittle (b) materials, respectively. Starting from the tool tip in the primary shear zone, the crack initiation (d-6) follows the cutting line. This is explainable due to the materials properties. Ductile materials have a large critical fracture strain, and the strain in the negative shear zone is smaller than the critical strain of the material. Thus, the crack initiates in the direction of the lowest resistance. During the crack-growth (d-7) stage, the tool makes the crack grow as well as deforms the workpiece so that the resulting crack growth seems to appear along the cutting line. The last stage is characterized by the positive burr (d-8), which remains on the workpiece corner. This marks the end of burr formation. Contrary to ductile materials, brittle materials have a small critical fracture strain, therefore, the direction of the pivoting point exhibits the smallest resistance. The crack initiation (b-6) propagates this way. The crack growth (b-7) takes place along the negative shear zone. The end of burr formation is built up by a negative burr (b-8) that remains on the workpiece edge as a result of a separation from the chip and that part of the workpiece that is above the negative shear line.

Continuous Cutting

Pre-Initiation

Initiation

Pivoting

Burr Development

1 1

2 2

3 3

4 4

5 5

Ductile Materials

Crack Initiation

Crack Growth

Positive Burr

6 6

7 7

8 8

Brittle Materials

Crack Initiation

Crack Growth

Negative Burr (Breakout)

Legend: primary shear zone plastic zone elastic zone workpiece / chip

6 6

7 7

8 8

Figure 1.5 Schematic of the Burr-Formation Process [6]

Min et. al. [7] proposed a burr formation model for a uniform burr and a crown burr which can be found in most of alloy steel, stainless steel, and some aluminum alloys. Their model is based on experimental observations using high speed camera and FEM simulations. Burr formation mechanism is divided into five stages: (a) steady-state, (b) initiation, (c) development, (d) initial fracture, and (e) final burr formation for both burr types in Table 1.1 and Table 1.2. The thrust force induced by many cutting parameters causes different initiation points and initial fracture locations, which leads to different burr types. During the steady-state cutting stage, material in front of the drill tip is removed as elements comprising that portion meet the failure criterion and a plastic zone appears near the center of the drill tip. As the drill advances, the plastic zone near the center of the drill tip reaches the exit surface of the workpiece at the burr initiation stage. As soon as the plastic zone reaches near the center of the hole on the exit surface, plastic deformation is initiated. Up to this point, material is mainly cut by the cutting edge of the drill. After the burr initiation point, bending mechanism slowly takes over cutting mechanism. For a uniform burr, this plastic zone appears at the exit surface of the workpiece when the drill almost reaches the exit surface. Hence, the layer between the exit surface and the drill tip is thin. By contrast, the plastic zone reaches the exit surface when the drill is far away from that surface and forms a thick plastic layer for a crown burr. The thickness of the layer at the burr initiation point defines burr formation behavior in the following stages: development and initial fracture. The thin layer of the plastic zone in the uniform burr does not have enough support to be cut by the drill and so rapid transition from cutting to bending occurs. Thus, very little cutting at the perimeter of the drill occurs during the development stage, Table 1.1 (c). The plastic zone that initially formed near the center of the drill area expands to the edge of the drill and plastic deformation spreads out. The thick layer of the plastic zone in the crown burr has more stiffness than that in the uniform burr. Hence, transition from cutting to bending is very slow, which enables more material to be cut during the development stage and allows very little expanding of the plastic zone to the edge of the drill, Table 1.2 (c). In the uniform burr, the material in front of the chisel edge of the drill undergoes mainly plastic deformation without cutting during the development stage and at certain point, is just pushed away by the chisel edge because the rotational cutting speed at the center of the drill is zero and the thin layer of the material cannot sustain cutting force. However, the material near the edge of the drill connected to the large material area that has enough stiffness to support cutting force still undergoes cutting and bending with high rotational cutting speed. Therefore, material near the edge of the drill becomes thinner and initial fracture occurs at the edge of the drill, Table 1.1 (d) and it leads to the formation of cap, Table 1.1 (e). However, in the crown burr, a larger thrust force induces plastic deformation earlier in the process. The thicker material layer in front of the chisel edge of the drill still undergoes plastic deformation and cannot be simply pushed away because it is connected to stiffer area that can support thrust force. A larger maximum strain is induced near center of the exit surface. When this maximum strain exceeds the fracture strain of the workpiece material, initial fracture occurs at the center of the drill, Table 1.2 (d) and the rest of material deforms plastically and forms a crown burr, Table 1.2 (e). The five stages of the uniform burr and the crown burr are compared with the proposed mechanism [8] and high-speed camera images (top view) [9] in Table 1.1 and Table 1.2.

Table 1.1 Burr formation mechanism of a uniform burr in AISI 304L [7] Proposed burr formation mechanism [8]

Burr formation mechanism

FEM simulation

High-speed camera image [9]

(a) Steady-state

(b) Initiation

(c) Development

(d) Initial fracture

(e) Final burr

Table 1.2 Burr formation mechanism of a crown burr in AISI 304L [7]

Burr formation mechanism

Proposed burr formation mechanism [8]

FEM simulation

High-speed camera image [9]

(a) Steady-state

(b) Initiation

(c) Development

(d) Initial fracture

(e) Final burr

1.4 Burr types

There exist tons of different burr classifications depending on application, manufacturing process, shape, formation mechanism and location, and so forth. The general burr classification by Gillespie and Blotter [10] is based on cause of formation. Poisson burr: The Poisson burr is a result of a materials tendency to bulge at the sides when compressed until permanent deformation occurs. The name Poisson burr derives from Poissons ratio, accounting for lateral deformation of materials, Figure 1.6.

Figure 1.6 Poisson burr [10]

Rollover burr: The rollover burr is basically a chip which is pushed out of the cutters path rather than being sheared. Typically, it is a long burr formed at the end of the cut. The formation of rollover burrs predominates in most cutting operations involving ductile materials, Figure 1.7.

Figure 1.7 Rollover burr [10]

Tear burr: The tear burr is the result of material tearing loose from the work piece rather than being sheared, Figure 1.8.

Figure 1.8 Tear burr [10]

Cut-off burr: The cut-off burr is the result of a separation from the raw material before the separation cut is finished. Whenever a part is allowed to fall back down before the cut is completed, a cut-off burr remains on the part. This burr type often occurs on saw cuts. Similar to this classification, another commonly used method to define and classify the burr is to look at its shape and formation mechanism. The reason why the shape plays an important role is that in most cases, it is closely related to the burr formation mechanism and in turn, proper selection of deburring technology and development of burr prevention/minimization strategy. Burrs representing combinations of the above mentioned types are most likely to be observed. But one mode of formation usually dominates Figure 1.9 shows some typical burrs found in drilling metals.

Figure 1.9 Typical drilling burr types [8]

Reference:
[1] Schfer, F., Gratbildung und Entgraten beim Umfangsstirnfrsen, VDI-Z 120, Nr. 1 / 2, 1978. [2] Ko, S. L., Dornfeld, D. A., A study on burr formation mechanisms, ASME Transactions, Journal of Engineering Materials and Technology, vol. 113, no. 1, pp. 75-87, 1991. [3] N. N., Werkstckkanten, Deutsches Institut fr Normung (DIN), Beuth Verlag Kln Berlin, DIN 6784, 1982. [4] Gillespie, L. K., Standard Terminology for Researchers of Burrs and Edge Finishing, World-wide Burr Technology Committee WBTC STD-02, 1996. [5] Link, R., Gratbildung und Strategien zur Gratreduzierung, Ph. D. Dissertation, RheinischWestsfaelische Technische Hochschule (RWTH) Aachen, 1992. [6] Hashimura, M., Chang, Y. P., Dornfeld, D. A., Analysis of Burr Formation Mechanism in Orthgonal Cutting, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 1-7, 1999. [7] Min, S., Dornfeld, D. A., Kim, J., Shyu, B., Finite Element Modeling of Burr Formation in Metal Cutting, International Journal of Machining Science and Technology, vol. 5, no. 3, pp. 307-322, 2001. [8] Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001. [9] Furness, R. J., Video Tape of Exit Burr Formation of Carbon Steel, Ford Motor Company, 1998. [10] Gillespie, L. K., Blotter, P. T., (1976), Formation and Properties of Machining Burrs, ASME Transactions, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74.

2. Burr metrology
2.1. Classification and standard 2.1.1. Classification of burrs in general machining
CATEGORY: Burr metrology SUB-CATEGORY: Classification and standard CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group proposed a burr classification scheme based on its formation mechanism regardless of machining process. A Poisson burr is formed by lateral flow of material, a roll-over burr by bending of material such as chip roll-over, a tear burr by tearing of chip from the workpiece (or when the punch tears the part from the stock in stamping process), a recast burr by redeposition of material, cutoff burr by incomplete cutoff of material, and finally a flash burr by flow of material into cracks. Basic characteristics of each type of burr were established and their empirical models were proposed. Also, burrs produced by many manufacturing processes were classified. KEY ISSUES FOR THIS PROGRAM  Classification of burrs based on formation mechanism in general machining STATUS: On going REFERENCE: [1] Gillespie, L. K., Burrs Produced by Drilling, Bendix Corporation Unclassified Topical Report, BDX-613-1248, 1975. [2] Gillespie, L. K., The Formation and Properties of Burrs, SME Technical Report, MRR75-03, 1975. [3] Gillespie, L. K., Blotter, P. T., Formation and Properties of Machining Burrs, Transactions of the ASME, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74, 1976.

2.1.1. Classification of burrs in general machining (Continued)

CATEGORY: Burr metrology SUB-CATEGORY: Classification and standard CONTACT INFORMATION: Kazuo Nakayama and Minoru Arai Yokohama National University, Japan ABSTRACT This research group proposed a general burr classification along with efforts on burr minimization. Machining burrs formed in various cutting operations were classified by the combination of two systems of classification: (1) by cutting edge directly concerned and (2) by the mode and direction of burr formation. Table 2.1 Burr classification [1] (1) Cutting edge directly concerned Major cutting edge Corner or minor cutting edge (2) Mode and direction of formation Backward flow Sideward flow Forward flow Leaning to feed direction M C

B (Backward or entrance burr) S (Sideward burr) F (Forward or exit burr) L (Leaned burr)

Figure 2.1 Various types of machining burrs [1]

KEY ISSUES FOR THIS PROGRAM  Classification of face milling burr  Burr minimization in face milling STATUS: Closed REFERENCE: Nakayama K., Arai, M., Burr Formation in Metal Cutting, Annals of the CIRP, vol. 36, no. 1, pp. 3336, 1987.

2.1.2. Classification of burrs in face milling

CATEGORY: Burr metrology SUB-CATEGORY: Classification and standard CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720, USA dornfeld@me.berkeley.edu http://lma.berkeley.edu
Machined surface

Tool

Major cutting edge

ABSTRACT This research group proposed a classification of milling burrs based on burr location, shape and mechanism. Several methods and classification schemes were proposed by this group. The milling burrs were classified according to three locations, five shapes and four burr formation mechanisms based on fractography.

Chip

Minor cutting edge

Figure 2.2 Cutting edges Table 2.2 Burr classification [1] Location Surface Machined surface Surface cut by minor edge Transition surface Surface cut by major edge Top surface Surface cut by major edge Top burr Name Exit burr Remains attaching to machined surface Shape (Macro view) Discontinuous Type Mechanism (Micro view) Ductile plus fracture (DF) Facture plus ductile (FD) Fracture (F) Completely ductile (CD)

Continuous Discontinuous (DC) Spiral (S) Continuous (C) Discontinuous Ragged Longitudinal

Side burr

The results in burr research were effective on the specific cases but it is difficult to apply to other conditions, because burrs found in production lines were various in shape and size. Therefore generalized and systematic understanding of formation mechanism for various burrs was required. Moreover the classification based on formation mechanism is considered to be useful to solve the burr problems in future. From the basic classification as described in the above table, this group has kept improving their classification and adding more feature onto it. One of the classifications is shown in Figure 2.3.

Figure 2.3 Burrs on various locations in face milling [3]

KEY ISSUES FOR THIS PROGRAM  Burr classification depending on burr location, shape, and formation mechanism in face milling STATUS: On going REFERENCE: [11] Hashimura, M., Hassamontr, J., Dornfeld, D.A., Effect of In-Plane Exit Angle and Rake Angles on Burr Height and Thickness in Face Milling Operation, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 13-19, 1999. [12] Hashimura, M., Ueda, K., Dornfeld, D.A., Manabe, K., Analysis of Three Dimensional Burr Formation in Oblique Cutting, CIRP Annals, vol. 44, no.1, pp. 27-30, 1995. [13] Hashimura, M., Dornfeld, D. A., Proposal of a Burr Classification Method Based on the Formation Mechanisms in Face Milling, Journal of the Japan Society of Precision Engineering, vol. 65, no. 6, pp. 872-877, 1999. [14] Hashimura, M., Dornfeld, D. A., Proposal of a Burr Classification Method Based on the Formation Mechanisms in Face Milling (2nd Report), Journal of the Japan Society of Precision Engineering, vol. 65, no. 7, pp. 1002-1007, 1999. [15] Meum, E., System for Burr Measurement, Diploma thesis, Norwegian University of Science and Technology, 2001.

2.1.3. Classification of burrs in drilling

CATEGORY: Burr metrology SUB-CATEGORY: Classification and standard TITLE: Classification of burrs in drilling of stainless steel (AISI 304L) and low alloy steel (AISI 4118) CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Burr classification was carried out based on the geometric characteristics, burr formation mechanisms, and sizes of the burrs. Two types of burrs, uniform burr (type I: small uniform burr, type II: large uniform burr) and crown burr, for stainless steel and three types of burrs, uniform burr (type I: small uniform burr, type II: large uniform burr), transient burr, and crown burr, for low alloy steel were found. Burr formation mechanisms for each burr type were proposed.

Figure 2.4 Typical drilling burr types [4]

KEY ISSUES FOR THIS PROGRAM  Classification of burrs in drilling of stainless steel (AISI 304L) and low alloy steel (AISI 4118) STATUS: On going REFERENCE: [1] Kim, J., Dornfeld, D. A., Furness, R., Experimental Study of Burr Formation in Drilling of Intersecting Holes with Gun Drill and Twist Drills, Technical Papers of NAMRI/ SME, pp. 39-44, 1999.

[2] Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Stainless Steel, Transactions of NAMRI/ SME, vol. 28, pp. 317-322, 2000. [3] Min, S., Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Low Alloy Steel, AISI 4118, Journal of Materials Processing Technology, vol. 113, no. 1-3, pp. 4-9, 2001. [4] Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001.

2.1.4. Standards on burr and edge

CATEGORY: Burr metrology SUB-CATEGORY: Classification and standard CONTACT INFORMATION: Kazuya Ohmori Iwata Denko Co. Ltd, Japan ABSTRACT This group surveyed many efforts on establishing standards for edge quality and burrs. Due to the lack of national or international standard on edge quality and burrs, there exist many semistandards depending on industry. The study reviewed briefly those standards in USA and Canada: Military standards, Industrial standards, In-plant standards etc. The standards prevalent in Germany and Japan were also reviewed.

KEY ISSUES FOR THIS PROGRAM  Burr standards STATUS: Closed REFERENCE: Ohmori, K., Investigations and Studies for Standards of Edge, Iwata Denko Company, Technical Report.

2.2. Measurement system and sensor 2.2.1. Burr size measurement using a capacitance sensor
CATEGORY: Burr metrology SUB-CATEGORY: Measurement system and sensor CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group used a capacitance sensor to develop an on-line burr measurement system. A non-contact capacitance gauging sensor was attached to an ultra precision milling machine which was used as a positioning system. The setup was used to measure burr profiles along the machined workpiece edges. Experimental procedures and results as well as the basic theoretical principles of the capacitance sensor and specifications of related equipment were proposed. The proposed scheme was accurate, easy to setup, and with minor modifications, readily applicable to automatic deburring processes. KEY ISSUES FOR THIS PROGRAM  Burr size measurement STATUS: Closed REFERENCE: Lee, S. H., Park, D. S., Dornfeld, D. A., Burr Size Measurement using a Capacitance Sensor, Proceedings of Second S. M. Wu Symposium on Manufacturing Science, SME, pp. 31-36, 1996.

2.2.2. Burr size measurement using a laser displacement sensor

CATEGORY: Burr metrology SUB-CATEGORY: Measurement system and sensor CONTACT INFORMATION: Ken-ichiro Shimokura Human Interface Laboratories Nippon Telegraph and Telephone Corp. Yoko 180, Japan k.shimokura@lab.ntt.co.jp Sheng Liu, Research Scientist Department of Mechanical Engineering Room 3-354 Massachusetts Institute of Technology 77 Massachusetts Ave, Cambridge, MA 02139 liudynac@mit.edu

ABSTRACT This research group used a laser displacement sensor (LDS) to measure the burr height in order to assist efficient robot deburring. A LDS can project a laser beam with no more than 230 Pm in beam diameter onto a reflective object surface. The sensor can estimate the travel distance of the laser beam between the target object and a receptor on the sensor with an accuracy as high as 0.5 Pm when measuring a white flat surface. Applications of this sensor are primarily for short distance on displacement measurement, such as sheet metal thickness, small gap width on printed circuit boards, or fluttering of rotating disks. The sensor was mounted on the deburring robot and the burr height was measured as the distance between the edge of the burr and the desired workpiece surface location. In order to evaluate the performance of this measuring system, the burr size was compared with other measurement results. The results showed good agreement with other measurements. KEY ISSUES FOR THIS PROGRAM  Burr size measurement STATUS: Closed REFERENCE: Shimokura, K., Liu, S., Programming Deburring Robots Based on Human Demonstration with Direct Burr Size Measurement, Proceedings of IEEE International Conference on Robotics and Automation, pp. 572-577, 1994.

2.2.1. Measurement of drilling burr by image processing technique

CATEGORY: Burr metrology SUB-CATEGORY: Measurement system and sensor CONTACT INFORMATION: Professor Yohichi Nakao Department of Mechanical Engineering Kanagawa University 3-27-1 Rokkakubasi, Kanagawa-ku, Yokohama 221-8686, JAPAN nakao@cc.kanagawa-u.ac.jp ABSTRACT This research group developed a measurement technique for drilling burr profile and size using an image processing technique. A key for measurement of the drilling burr by an image processing technique is to take whole image of drilling burr at once. The images of the drilling burr were sampled using four prism mirrors and a CCD camera. In order to obtain drilling burr features from sampled drilling burr images, an algorithm to calculate both profile of height and thickness of the drilling burr was developed. Influences of setting error between the CCD camera and measured objects setting on the bench of the measurement system upon measurement accuracy were also considered. A relationship between measured profile of circular cylinder and the setting error were analyzed. Based on the relationship, a correction procedure of the set up error was developed and used for actual measurements of drilling burr. Developed computer software calculated not only profile of both burr height and thickness but also various statistical values of the burr geometry such as average, standard deviation of burr height and thickness and etc. Type of drilling burr geometry was also classified automatically based on the obtained statistical data. KEY ISSUES FOR THIS PROGRAM  Development of drilling burr measurement system STATUS: On going REFERENCE: Nakao, Y., Measurement of Drilling Burr by Image Processing Technique, Proceedings of ASPE 16th Annual Meeting, pp. 309-312, 2001.

3. Understanding of burr formation

3.1. Analytical modeling 3.1.1. Analytical modeling of burr formation in orthogonal cutting
CATEGORY: Understanding of burr formation SUB-CATEGORY: Analytical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a quantitative analytical model of burr formation for ductile materials which does not include fracture during orthogonal machining. The model predicts burr size from given cutting conditions, material properties, and tool geometry. The model also proposed the burr formation mechanism which is divided into three parts - initiation, development, and formation of the burr with appropriate assumptions. The mechanisms proposed are based on the observation of the behavior of workpiece material during orthogonal machining on commercial plasticine. The model was validated with the experiments that orthogonal machining inside a scanning electron microscope at low speed was done with a copper workpiece and Al 6061-T6, Al 2024-T4 and Al 390 were cut on a modified milling machine over a range of cutting speeds. KEY ISSUES FOR THIS PROGRAM  Understanding of burr formation process for ductile materials (copper and aluminum alloy) in orthogonal cutting STATUS: Closed REFERENCE: Ko, S. L., Donrfeld, D. A., A Study on Burr Formation Mechanism, ASME Transactions, Journal of Engineering Materials and Technology, vol. 113, no. 1, pp. 75-87, 1991.

3.1.2. Analytical modeling of edge breakout in orthogonal cutting

CATEGORY: Understanding of burr formation SUB-CATEGORY: Analytical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a burr formation/edge breakout model for orthogonal cutting based on the observation of SEM micro-machining tests. It is found that a negative deformation plane begins to form when the steady-state chip formation stops as the tool approaches the end of the cut. Plastic bending and shearing of the negative deformation plane contributes to the burr formation, while crack propagation along the plane causes the breakout. Simulated orthogonal cutting experiments using copper, Al 2024-T4, and Al 6061-T6 were performed with a modified impact machine to verify the model. The tests showed excellent agreement with the model predictions. A criterion for estimating fracture in the burr formation process is established from the strain analysis. The formation of the negative deformation plane plays an important role in the mechanism of burr formation and breakout. Bending and shearing are the dominant mechanisms for burr formation while crack propagation along the negative deformation plane is the dominant mechanism for breakout. The negative deformation angle is very sensitive to the exit angle and thus influences the equivalent strain when burr formation initiates. Burr height and breakout length increase proportionally with the depth of cut. The fracture strain of the workpiece determines at what exit angle breakout will occur instead. KEY ISSUES FOR THIS PROGRAM  Understanding of edge breakout phenomena in orthogonal cutting STATUS: Closed REFERENCE: Chern, G., Donrfeld, D. A., Burr/Breakout Model Development and Experimental Verification, ASME Transactions, Journal of Engineering Materials and Technology, vol. 118, no. 2, pp. 201-206, 1996.

3.1.3. Analytical modeling of burr formation and fracture in oblique cutting

CATEGORY: Understanding of burr formation SUB-CATEGORY: Analytical modeling CONTACT INFORMATION: Professor Sung-Lim Ko Department of Mechanical Design and Production Engineering Kon-kuk University 93-1 Mojin-dong, Kwanjin-gu Seoul 133-701, Korea slko@kkucc.konkuk.ac.kr http://www.premalab.re.kr/intro/intro.php Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Based on previous efforts on modeling of burr formation and edge breakout in orthogonal cutting, this research group further developed a modified model for burr formation and fracture in oblique cutting. For the oblique-chip-formation model, Rubensteins assumption that chip removal occurs as a result of normal tool/workpiece relative movement is used to determine the material properties of the chip and the geometry of chip formation. It is assumed that roll-over burr is always formed in the cutting direction. Thus burr formation in oblique cutting is considered as the accumulation of burr formation in segmented orthogonal cutting in the cutting-direction plane. A result of the analysis was that the burr size or fracture location decreases as the inclination angle (the angle between the cutting edge and the normal to the cutting direction) of oblique cutting increases. Two kinds of burr formation or fracture were observed in experiments: uniform and inclined burr formation or fracture. Uniform burr formation or fracture can be predicted using the modified model. In the case of inclined burr formation, the equivalent initial tool distance and fracture location are determined using the values obtained in uniform burr formation and the inclination stage. KEY ISSUES FOR THIS PROGRAM  Understanding of burr formation and edge breakout in oblique cutting  Relationship between inclination angle and burr formation/edge breakout STATUS: On going REFERENCE: [1] Ko, S. L., Donrfeld, D. A., Burr Formation and Fracture in Oblique Cutting, Journal of Materials Processing Technology, vol. 62, no. 1-3, pp. 24-36, 1996. [2] Hashimura, M., Ueda, K., Dornfeld, D. A., Manabe, K., Analysis of Three Dimensional Burr Formation in Oblique Cutting, CIRP Annals, vol. 44, no. 1, pp. 27-30, 1995. [3] Hashimura, M., Chang, Y. P., Dornfeld, D. A., Analysis of Burr Formation Mechanism in Orthgonal Cutting, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 1-7, 1999.

3.1.4. Analytical modeling of burr formation in milling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Analytical modeling CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group proposed the mechanisms causing machining burrs and four analytical models that predict burr properties. The study found that three basic mechanisms, lateral deformation, chip rollover, and material tearing, were involved. Both the theory and experimental results indicated that machining burrs could not be prevented by changing machining parameters alone. KEY ISSUES FOR THIS PROGRAM  Understanding of the formation and properties of milling burrs STATUS: Closed REFERENCE: [4] Gillespie, L. K., Blotter, P. T., Formation and Properties of Machining Burrs, ASME Transactions, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74, 1976. [5] Gillespie, L. K., The Formation and Properties of Burrs, SME Technical Report, MRR75-03, 1975.

3.1.5. Analytical modeling of burr formation in drilling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Analytical modeling CONTACT INFORMATION: Professor L. Ken Lauderbaugh Saunders Mechanical and Aerospace Engineering University of Colorado at Colorado Springs Colorado Springs, CO 80933-7150, USA lksaunders@engineering.uccs.edu ABSTRACT This research group analyzed the mechanics of the formation of exit burrs for drilling metals and developed a burr formation model where the material in front of the drill was modeled as a circular plate of varying thickness. The drilling thrust force was distributed as a pressure along the plate. The stress state was then calculated based on this loading. Material removal continues until a failure condition was reached. At the point of failure of the plate the remaining material was bent out to form the burr. The model also included temperature effects. Experimental verification was conducted on 2024-T351 aluminum and on 7075-T561 aluminum. Two types of drill geometry were considered. The model accurately predicts the experimental data. KEY ISSUES FOR THIS PROGRAM  Understanding of drilling burr formation STATUS: Closed REFERENCE: [1] Saunders, L. L., Mauch, C. A., An Exit Burr Model for Drilling Metals, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 123, no. 4, pp. 562-566, 2001. [2] Mauch, C. A., Saunders, L. Ken L., Modeling the drilling process. An analytical model to predict thrust force and torque, Winter Annual Meeting of the American Society of Mechanical Engineers Materials Division, vol. 20., pp. 59-65,1990.

3.1.6. Modeling of burr formation at various exit surface geometry in drilling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Analytical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a model to explain partial burr formation when the exit surface is neither normal to drill path nor flat. This can be found in many applications such as intersecting holes and holes on inclined exit surface. An effective interaction angle was newly defined and the concept of degree of plastic deformation was introduced in order to explain this phenomenon. The burr forming location predicted from the effective interaction angle was verified with experimental results. The attempt to avoid burr formation has been made by design new tool and feed motion. KEY ISSUES FOR THIS PROGRAM  Understanding of drilling burr formation STATUS: On going REFERENCE: Min, S., Dornfeld, D. A., Nakao, Y., Influence of Exit Surface Angle on Drilling Burr Formation, ASME Trans., Journal of Manufacturing Science and Engineering, Vol. 125, No. 4, pp. 637-644, 2003.

3.2. Empirical modeling 3.2.1. Exit failure in interrupted cutting

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: A. J. Pekelharing Tech Hochsch Delft, The Netherlands ABSTRACT This research group investigated influence of interrupted cutting in terms of tool exits in relation to burr formation. In general, interrupted cutting yields a reasonable tool life only when feeds and speeds are kept lower than in continuous cutting and tool geometry is adapted. The entry shock was blamed for this but the tool exit was considered harmless or of minor influence. They conducted a simple discriminating test showing that the exit could cause immediate and progressive chipping; if that is the case the possible fatigue failure from the entry shock was of no importance. In orthogonal cutting on steel, the first exit destroyed a sharp carbide cutting edge at all feeds, speeds and types of carbide. Inclination of the exit face of the workpiece, within practical limits, did not prevent this damage. The mechanism of chip formation changed into burr formation near the end of the cut completely (negative shear) which explained the damage. KEY ISSUES FOR THIS PROGRAM  Influence of tool exit in interrupted cutting STATUS: Closed REFERENCE: [1] Pekelharing, A. J., Exit Failure in Interrupted Cutting, Annals of the CIRP, vol. 27, no. 1, pp. 510, 1978. [2] Pekelharing, A. J., Exit Failure of Cemented Carbide Face Milling Cutters, Part I Fundamentals and Phenomena, Annals of the CIRP, vol. 33, no. 1, pp. 47-50, 1984.

3.2.2. Effect of axial rake angle on burr formation in face milling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group investigated the influence of the axial rake angle of the tool on burr formation in face milling. Burrs created with various axial rake angles of the tools and cutting conditions were observed. To model the state of the continuous cutting, the chip flow angle calculated with cutting conditions was used. To describe the deformation type at the workpiece edge, the concept of exit order of the cutting edge, which can be calculated with the geometry of the tool and workpiece edges, was proposed. The chip flow angle and exit order are used to understand the burr formation mechanism in face milling. To vary the chip flow angle and exit order, depth of cut, feed and axial rake angle of tools were varied. As the results, it was verified that deformation formed in continuous cutting and tool exit has effect on burr size in face milling. As the chip flow angle increased, the exit burr thickness decreased and side burr thickness increased. As the axial rake angle decreased, the exit burr thickness increased with effect of the exit order. These chip flow angle and exit order are considered to be important factors on burr formation in milling. KEY ISSUES FOR THIS PROGRAM  Parametric study of tool geometry(axial rake angle) influence on burr formation in face milling  Modeling of burr formation through chip flow angle and exit order of the tool STATUS: On going REFERENCE: Hashimura, M., Dornfeld, D. A., Effect of Axial Rake Angle on Burr Formation in Face Milling, Journal of Japan Society of Precision Engineering, vol. 64, no. 11, pp. 1658-1663, 1998.

3.2.3. Effect of in-plane exit angle on burr formation and classification of burrs in face milling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu G. Barrow Department of Mechanical Engineering University of Manchester Institute of Science and Technology P.O. Box 88, Sackville St. Manchester, M60 1QD, U.K. http://www.me.umist.ac.uk/staffpgs/GB.htm ABSTRACT This research group investigated three-dimensional characteristics of burr formation in face milling with respect to in-plane exit angle using stainless steel (AISI 304L). An important aspect of the three-dimensional effects is the exit order of the tool edges because the burr remains near the final exit position of the tool along the workpiece edge. The geometric parameters of the workpiece and tools were varied to change exit order in the workpiece around the cutting edge. The exit burr on the exit surface and the side burr on transition surface of workpiece were analyzed. The effect of in-plane exit angle and radial rake angle on burr formation were shown and the burr formation mechanism for each burr was also discussed. KEY ISSUES FOR THIS PROGRAM  Concept of exit order and in-plane exit angle and their influence on burr formation in face milling STATUS: On going REFERENCE: [1] Hashimura, M., Hassamontr, J., Dornfeld, D.A., Effect of In-Plane Exit Angle and Rake Angles on Burr Height and Thickness in Face Milling Operation, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 13-19, 1999. [2] Hashimura, M., Ueda, K., Manabe, K., Dornfeld, D. A., Effect of In-plane Exit and Radial Rake Angle on Burr Formation in Face Milling, Journal of the Japan Society of Precision Engineering, vol. 66, no. 1, pp. 85-90, 2000. [3] Olvera, O., Barrow, G., Influence of exit angle and tool nose geometry on burr formation in face milling operations, Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture, vol. 212, no. 1, pp. 59-72, 1998.

3.2.4. Various burrs in square shoulder face milling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: G. Barrow Department of Mechanical Engineering University of Manchester Institute of Science and Technology P.O. Box 88, Sackville St. Manchester, M60 1QD, U.K. http://www.me.umist.ac.uk/staffpgs/GB.htm ABSTRACT This research group investigated the influence of the main cutting parameters on various burrs produced in face milling operations, namely exit burr in the cutting direction, exit burr in the feed direction and the burr formed at the top edge in a square shoulder face milling operation. Feed per tooth, cutting velocity, axial depth of cut, and exit angle were the cutting parameters investigated. The effects of mode of milling tool nose geometry and tool coating were also investigated to a lesser extent. The results showed that exit angle and depth of cut are the cutting parameters which had a major influence on the exit burr in the cutting direction, whereas the exit burr in the feed direction was mainly affected by depth of cut. The top burr was very small and only little influenced by cutting conditions. It was also shown that down-milling could effectively eliminate burr formation in some cases, whereas unfavorable tool nose geometry doubled the burr size. KEY ISSUES FOR THIS PROGRAM  Burr formation on various locations in face milling  Empirical evaluation of tool geometry on burr formation STATUS: On going REFERENCE: Olvera, O., Barrow, G., An Experimental Study of Burr Formation in Square Shoulder Face Milling, International Journal of Machine Tools and Manufacture, vol. 36, no. 9, pp. 1005-1020, 1996.S

3.2.5. Burr formation in side-milling cutters

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group conducted study to determine how side-milling cutter geometry and machining conditions affect the size of burrs produced. The thickness, length, and hardness of burrs produced on all eight edges of side0milled slots in 303Se stainless steel were measured. The formation mechanism of side-milling burrs was also proposed. Study indicated that slower feed rate generally result in thinner burrs. The eight different burrs, produced by a side-milling cutter in a single cut, all responded differently to changes in cutting conditions. Cutters having a non-zero helix angle produce longer and thicker than those with a zero helix angle. Radial depth of cut did not influence burr size. Full radius keyseat style cutters with Master Cut tooth geometry produced longer and thicker burrs than similar cutters with square tooth corners. Burrs in 17-4 PH stainless steel were much smaller than those in 303Se stainless steel. Empirical models for burr properties were developed.

KEY ISSUES FOR THIS PROGRAM  Understanding burr formation by side-milling cutters STATUS: Closed REFERENCE: Gillespie, L. K., Burrs Produced by Side-Milling Cutters, Bendix Corporation Unclassified Topical Report, BDX-613-1303, 1975.

3.2.6. Burr formation in drilling small holes

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group investigated burr formation in a small hole of diameter less than 1 mm. The burrs from these processes can be particularly difficult to remove. A two level replicated fractional factorial design was used to investigate the effects of five factors on the exit burr thickness and height in the drilling of holes of diameter less than one millimeter in 304L stainless steel. The factors investigated were feed per revolution, cutting speed, drill pecking, drill wear and drill material. Increasing feed and cutting speed were found to increase the burr height and thickness, and the effect of increasing the feed was more pronounced at high cutting speeds. The effect of increase cutting speed was related to the increased cutting temperature observed in drilling holes with relatively high length to diameter ratios. Worn drills were shown to increase burr size and the variation in burr size for constant cutting conditions. Drill pecking was determined to be a stabilizing factor which increased the robustness of the burr formation process to changes in feed and cutting speed. For values of the undeformed chip thickness (feed) greater than 12 Pm, the ratio between the burr height and the undeformed chip thickness in drilling stainless steel was a constant equal to approximately six. The values of this constant increase with increasing spindle speed. This constant may be a fundamental property of the work material for particular tool geometry in regions of undeformed chip thickness where the tool performs a cutting, rather than plowing action. KEY ISSUES FOR THIS PROGRAM  Burr characteristics in small holes (of diameter less than 1 mm)  The fractional factorial experimental design STATUS: Closed REFERENCE: [1] Stein, J. M., Dornfeld, D. A., Analysis of the Burs in Drilling Precision Miniature Holes, Proceedings of the 1995 ASME International Mechanical Engineering Congress and Exposition, San Francisco, CA, USA, vol. 2-1, pp. 127-148, 1995. [2] Stein J. M., Dornfeld, D. A., Burr Formation in Drilling Miniature Holes, CIRP Annals, vol. 46, pp. 63-66, 1997.

3.2.7. Drilling burr formation in titanium alloy (Ti-6Al-4V)

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Titanium alloy (Ti-6Al-4V) plates were drilled to investigate the effects of tool geometry as well as process conditions on the drilling burr formation. Drilling was done with solid carbide tools with and without coolant and high speed cobalt drills without coolant. Four distinct burr types were observed. During dry cutting, a rolled back type burr was observed at high feed rates and cutting speeds and is believed to be due to thermal effects. A ring type burr was observed when drilling with coolant. While cutting conditions had little effect on the burr sizes formed, drill geometry (helix angle, split point vs. helical point, lip relief angle and point angle) affected burr thickness and height. KEY ISSUES FOR THIS PROGRAM  Burr formation in titanium alloy (Ti-6Al-4V)  Thermal effect of titanium alloy machining STATUS: Closed REFERENCE: Dornfeld, D. A., Kim, J., Dechow, H., Hewson, J., Chen, L. J., Drilling Burr Formation in Titanium Alloy, Ti-6Al-4V, CIRP Annals, vol. 48, no. 1, pp. 73-76, 1999.

3.2.8. Influence of workpiece exit angle on burr formation in drilling intersecting holes
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Intersecting drilled holes frequently occur in many production situations. In a drilling operation, inclination or curvature of the exit surface causes a variation of the workpiece exit angle around the periphery of the hole, unlike the constant exit angle value of 90 degrees observed in planar exit surface drilling. A fractional factorial experimental design was used to investigate the importance of drilling process parameters, drill point geometry and drilling workpiece exit angles in the modeling of the drilling burr formation process for 0,036 (0.91mm) intersecting holes in 304L stainless steel. The workpiece exit angle in drilling is an important factor in determining burr size and shape. The shape of the burrs around on-axis holes was more uniform than the shape for off-axis holes, and this difference was probably determined by the variation in exit angles between the two configurations. The burrs in on-axis hole drilling are more desirable in shape than those in off-axis hole drilling, but they may be less predictable in size. The burrs in off-axis hole drilling occur in a fairly predictable pattern and the burr sizes for in both on-axis and off-axis intersecting hole drilling. KEY ISSUES FOR THIS PROGRAM  Burr formation in intersecting holes STATUS: On going REFERENCE: Stein J. M., Dornfeld D. A., Influence of Workpiece Exit Angle on Burr Formation in Drilling Intersecting Holes, Transactions of NAMRI/ SME, vol. 24, pp. 39-44, 1996.

3.2.9. Burr formation in drilling of intersecting hole with gun and twist drills
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group investigated the mechanism of the burr formation in drilling of intersecting holes with a gun drill and two types of twist drills. Three different inclination angles, feed rates and cutting speeds were selected to determine their influences on burr formation. The burr formation mechanism of a gun drill as well as a twist drill was proposed and a qualitative comparison of burr shapes created by different drill types was performed. The maximum burr height in each condition was measured. It was found that geometric parameters played the most dominant role in determining burr size. KEY ISSUES FOR THIS PROGRAM  Burr formation in intersecting holes using gun and twist drills STATUS: Closed REFERENCE: Kim, J., Dornfeld, D. A., Furness, R. J., Experimental Study of Burr Formation in Drilling of Intersecting Holes with Gun Drill and Twist Drills, Technical Papers of NAMRI/ SME, pp. 39-44, 1999.

3.2.10. Statistical study of burr formation and hole quality in drilling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Richard J. Furness Manufacturing Systems Department Materials Research Laboratory Ford Motor Company Dearborn, MI, USA ABSTRACT A statistical study of the effects of feed, speed, and coolant on exit burrs, drill caps, and various hole quality measures of oversize, out-of-roundness, location error, angularity error, and taper was conducted using several drill designs. The effects of workpiece surface condition, geometrical variation among drills, and drill wear were qualitatively observed. This study included the following drill designs: (1) radial lip, (2) 135 split-point, (3) 150 split-point, parabolic flute, and (5) 118 conical point, general purpose drills. The results indicated that the effect of cutting conditions and coolant on exit burrs, drill caps, and hole quality was secondary to that of drill geometry. The magnitude and trend of estimated factor effects varied for each drill. The presence of drill caps was dependent on drill style; the radial lip drill was the only design that did not create caps. In separate tests with additional drill designs, Bickford and double-angle point drills also did not produce drill caps. The 135 and 150 split-point drills had the best overall performance. These drills had very good size control, small roundness and location errors, small push-out burrs, and also required less thrust force. Unfortunately, the split-point drills consistently create drill caps. With the exception of hole location error, the hole quality was not predictably or significantly affected by the cutting conditions. Although these results were not expected, they had the important positive implication that production rates may be increased without sacrificing hole quality. The drilling feeds and speeds would be constrained by factors other than hole quality, such as drill wear, drill breakage, or force, torque, and power limits. KEY ISSUES FOR THIS PROGRAM  Burr formation and hole quality by various drill types and cutting conditions STATUS: Closed REFERENCE: Furness, R. J., Lander, W. R., An Experimental Study of Exit Burr Formation and Hole Quality for Twist Drilling, Ford Motor Company Technical Report, SR-95-069, 1995.

3.2.11. Relationships between hole quality and drilling forces

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: A. Thangaraj, M. Langenstein Department of Mechanical Engineering-Engineering Mechanics Michigan Technology University Houghton, Michigan ABSTRACT The main objective of this research project was to study the static and dynamic characteristics of hole quality measures and drilling forces under various cutting conditions and investigate relationships among process parameters, hole quality measures and drilling forces. The experimental work consisted of drilling holes in blocks of cast iron using HSS and carbide-tipped drills, while measuring the drilling forces using a dynamometer. The surface finish and the out-ofroundness of the resulting holes were then measured using appropriate instruments. The tests were carried out at several different cutting conditions while making sure that drill wear did not play a dominant role. A strong correlation was discovered between some of the most common surface roughness parameters, namely the arithmetic mean of the deviations, the average height difference and the maximum peak-to-valley height, and the surface speed of the drill. Further, good correlations were found between the same roughness parameters and the root-mean-square of one of the radial forces. KEY ISSUES FOR THIS PROGRAM  Relationships between hole quality and drilling forces STATUS: Closed REFERENCE: Thangaraj, A., Langenstein, M., An Investigation into the Relationship between Hole Quality and Drilling Forces, Proceedings of Manufacturing International 90 Part 4: Advances in Materials and Automation, Atlanta, GA, USA, pp. 149-157, 1990.

3.2.12. Effect of process parameters on surface finish of drilled holes

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor Srinivasan Chandrasekar, chandy@ecn.purdue.edu http://roger.ecn.purdue.edu/~tribmat/chandy.html Professor W. Dale Compton dcompton@ecn.purdue.edu http://roger.ecn.purdue.edu/~tribmat/compton.html School of Industrial Engineering Purdue University West Lafayette, IN 47907-1287 ABSTRACT This research group investigated the effect of process parameters on the surface finish of drilled holes. Drills made of high-speed steel, tungsten carbide, TiN-coated HSS, silicon nitride and aluminum oxide were used to drill holes in cast iron, 1018 steel and 6061 aluminum. The effect of chip morphology on finish was studied by controlled chip breakage achieved through the application of a controlled, superimposed modulation in the direction of drill feed. It was found that drill material had the most important influence on surface finish with ceramic drills consistently giving the smoothest finish. Furthermore, the surface finish in the middle portion of a hole was consistently worse than at the top and at the bottom. The application of a lubricant mist during drilling was found to slightly improve the finish while chip breakage had a small but varying influence. The application of a superimposed modulation which resulted in consistent chip breakage was, however, found to reduce the height of the burr at the exit of a hole. The observations suggested that rubbing of the drill against the hole surface may be the primary determinant of hole finish. The accuracy of a replica to assess surface finish of a hole was also established. KEY ISSUES FOR THIS PROGRAM  Effect of process parameters on surface finish of drilled holes STATUS: Closed REFERENCE: Ramaswamy, D., Tucker, A., Olmez, A., Chandrasekar, S., Compton, W. D., A Study of the Effect of Process Parameters on Surface Finish of Drilled Holes, Transactions of NAMRI/SME, vol. 28, pp.227-232, 2000.

3.2.13. Entrance and exit burr formation in drilling and reaming

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT An investigation was conducted to determine the influence of variables in controlling the size and repeatability of drilling burrs to minimize burr-removal costs and improve part quality. Experimental study was conducted to determine the influence of drill geometry and drilling techniques upon the size of the burr produced. The thickness and length of both entrance and exit burrs produced from 303Se and 17-4PH stainless steel, 1018 steel, and 6061-T6 aluminum were measured. Entrance burrs were typically triangular in cross section with length equal to thickness; exit burrs were rectangular with length from two to ten times the thickness. For stainless steel, exit burr thickness and length were proportional; no similar relationship was found for other materials. For some materials, decreasing the feed rate also decreases the exit-burr length. Under proper machining conditions, reaming after drilling resulted in smaller burrs than those produced by drilling alone. KEY ISSUES FOR THIS PROGRAM  Burr formation in both entrance and exit side of various workpiece materials in drilling and reaming STATUS: Closed. REFERENCE: [1] Gillespie, L. K., Burrs Produced by Drilling, Bendix Corporation Unclassified Topical Report, BDX-613-1248, 1975. [2] Gillespie, L. K., Effects of Drilling Variables on Burr Properties, Bendix Corporation, Unclassified Topical Report, BDX-613-1502, 1976.

3.2.14. Study on mechanism and similarity of burr formation in face milling and drilling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Koya Takazawa Kanagawa Institute of Technology Kamakura, Kanagawa, Japan bestjap@juno.ocn.ne.jp ABSTRACT This research group conducted comparative study on burrs produced in face milling and drilling. The workpiece used in the experiment was carbon steel for machine structural use (S45C in JIS, 179HB). The mechanism of burr formation in face milling was similar to that in drilling. Namely, in both cutting operations the sudden decrease of burr height, which is caused by the separation of the tip of the burr (secondary burr formation), occurred and the influence of depth of cut and feed rate on burr formation was also similar. KEY ISSUES FOR THIS PROGRAM  Comparative study on burr formation in face milling and drilling STATUS: Closed REFERENCE: [1] Kitajima, K., Miyake, T., Yamamoto, A., Tanaka, Y., Takazawa, K., Study on Mechanism and Similarity of Burr Formation in Face Milling and Drilling, Technology Reports of Kansai University, no. 32, 1990. [2] Miyake, T., Yamamoto, A., Kitajima, K., Tanaka, Y., Takazawa, K., Study on Mechanism of Burr Formation in Drilling. Deformation of Material during Burr Formation, Journal of the Japan Society of Precision Engineering, vol. 57, no. 3, pp. 485-490, 1991.

3.2.15. Formation and properties of burrs in various machining processes

CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group conducted experimental investigation on burr formation in various machining processes. Experiments on milling, drilling, turning and grinding processes were conducted. Based on analysis of experimental results, three basic burr formation mechanisms were found. They are lateral deformation, bending and material tearing. Other types of burr-like material formation such as material re-deposition, incomplete cutoff and flash formation were also observed. Each of the basic mechanisms was described individually for each process. Some typical burr properties were established for several machining processes. KEY ISSUES FOR THIS PROGRAM  Understanding of formation and properties of machining burrs STATUS: Closed REFERENCE: [1] Gillespie, L. K., The Formation and Properties of Burrs, SME Technical Report, MRR75-03, 1975. [2] Gillespie, L. K., Burrs Produced by Drilling, Bendix Corporation Unclassified Topical Report, BDX-613-1248, 1975. [3] Gillespie, L. K., Burrs Produced by Side-Milling Cutters, Bendix Corporation Unclassified Topical Report, BDX-613-1303, 1975. [4] Gillespie, L. K., Effects of Drilling Variables on Burr Properties, Bendix Corporation, Unclassified Topical Report, BDX-613-1502, 1976. [5] Gillespie, L. K., Blotter, P. T., Formation and Properties of Machining Burrs, ASME Transactions, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74, 1976.

3.3. Computer based modeling 3.3.1. Finite element modeling of burr formation in orthogonal cutting
CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group studied burr formation mechanism in orthogonal cutting using a finite element method (FEM). The study proposed a basic framework for and conceptual understanding of the burr formation process based upon the material properties of the workpiece. In order to verify this framework and explain the basic phenomena in the burr formation process, the deformation at the edge of the workpiece was analyzed using a finite element method. Burr formation mechanisms for ductile and brittle materials were proposed from FEM analysis and experimental observations. Micro-machining tests under an optical microscope and a scanning electron microscope using Al 2024-O and copper were also conducted to observe the burr formation process. The feed rate and tool edge radius were varied and the resulting burr formation observed. FEM analysis of burr formation in this material and observation of the deformation at the workpiece edge in the micromachining test verified the proposed conceptual understanding of the burr formation process. For the experimental conditions examined, all of the burrs in Al 2024-O were negative burrs, that is, edge breakout. As the feed was increased, two effects were observed. One effect was an increase in the resulting burr thickness. Another effect, which was observed during the burr initiation stage while machining with a sharp tool, was an increase in both the distance and depth of the initial pivoting point of the burr from the tool edge.

(a) Steady-state

(b) Initiation (c) Development

(d) Pivoting

(e) Final

(f) Burr

(g) Steady-state

(h) Initiation

(i) Pivoting

(j) Final

(k) Burr

Figure 3.1 Burr formation processes by FEM and SEM

Figure 3.2 Schematic illustration of the burr formation process [1] KEY ISSUES FOR THIS PROGRAM  FE modeling of burr formation in orthogonal cutting  Burr formation mechanisms for ductile and brittle materials  Micro-machining of aluminum alloy (Al 2040-O) and copper for validation experiment STATUS: Closed REFERENCE: [1] Hashimura, M., Chang, Y. P., Dornfeld, D. A., Analysis of Burr Formation Mechanism in Orthgonal Cutting, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 1-7, 1999. [2] Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part I, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 221-228, 2000.

3.3.2. Finite element analysis of the influences of exit angle and rake angle on burr formation in orthogonal cutting
CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group investigated the influences of exit angles of the workpiece and tool rake angles on burr formation processes in 304L stainless steel using finite element models in orthogonal cutting. Based on the metal cutting FE simulation procedure, a series of stress and strain contours and final burr/breakout configurations were obtained. The burr formation mechanisms with respect to five different exit angles were found, and duration of the burr formation process increased with an increase of exit angle, resulting in different burr/breakout configurations. Based on the development of negative shear stress in front of the tool tip, the tool tip damage, what is called chipping, was investigated. Also, with fixed cutting conditions and workpiece exit geometry, the influence of the rake angle was found to be closely related to the rate of plastic work in steady-state cutting because the larger the rate of plastic work in steady-state cutting, the earlier the burr initiation commences. KEY ISSUES FOR THIS PROGRAM  Parametric study of burr formation with respect to exit angle of the workpiece and rake angle of the tool using FE model  Relationship between burr/breakout and cutting parameters STATUS: Closed REFERENCE: Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part II - The Influences of Exit Angle, Rake Angle, and Backup Material on Burr Formation Processes, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 229-237, 2000.

3.3.3. Finite element modeling of burr formation in oblique cutting

CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group studied burr formation mechanism in oblique cutting using a rigid-plastic FEM (RPFEM) which is effective for analyzing a large plastic deformation field. The results of cutting experiments and computer simulation of oblique cutting conducted in order to understand threedimensional burr formation and the effect of the tool inclination angle are presented. Cutting experiments were carried out in a scanning electron microscope with a micro-machining device. Two types of burr were observed: exit burr on the exit edge of the workpiece and side burr on the side of the workpiece. The exit burr in oblique cutting was smaller than in orthogonal cutting, while the side burr in oblique cutting was larger than its orthogonal counterpart. The FE simulation showed good qualitative agreement with experimental data on both burr shape and cutting forces.

Figure 3.3 Burr formation mechanisms for orthogonal and oblique cutting [1] KEY ISSUES FOR THIS PROGRAM  FE modeling of burr formation in oblique cutting  Relationship between inclination angle and burr formation/edge breakout STATUS: Closed

REFERENCE: [1] Hashimura, M., Ueda, K., Dornfeld, D.A., Manabe, K., Analysis of Three Dimensional Burr Formation in Oblique Cutting, CIRP Annals, vol. 44, no.1, pp. 27-30, 1995. [2] Ko, S. L., Donrfeld, D. A., Burr Formation and Fracture in Oblique Cutting, Journal of Materials Processing Technology, vol. 62, no. 1-3, pp. 24-36, 1996.

3.3.4. Finite element analysis of mechanical state on sequentially machined surfaces

CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor Yuebin B. Guo Department of Mechanical Engineering The University of Alabama Tuscaloosa, Alabama 35487-0276, USA yguo@coe.eng.ua.edu http://www.eng.ua.edu/~yguo/ ABSTRACT This research group developed a thermo-elastic-viscoplastic explicit FE model to predict effects of sequential orthogonal cuts on the mechanical state and cutting mechanisms in a machined layer. Residual stress distribution was significantly changed and cutting mechanisms slightly changed in sequential cuts. A method to compressively pre-stress a sequentially machined surface was proposed by planning the uncut chip thickness. Effects of unloading of cutting forces, cutting temperatures, and clamping forces on the residual stress distribution were evaluated. KEY ISSUES FOR THIS PROGRAM  FE modeling of surface condition on sequential orthogonal cutting STATUS: Closed REFERENCE: Guo, Y. B., Liu, C. R., FEM Analysis of Mechanical State on Sequentially Machined Surfaces, Machining Science and Technology, vol. 6, no. 1, pp. 21-41, 2002.

3.3.5. Finite element modeling of burr formation in drilling

CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT A finite element model for drilling burr formation was developed. Two typical burr types, a uniform burr and a crown burr, were simulated with this model. Through these simulations, drilling burr formation mechanisms for both types of burrs were explained. This research has been expanded to modeling of inter-layer burr formation and micro-burr formation and drill design. Table 3.1 Drilling burr formation processes

Uniform burr
Steady-state cutting

Crown burr
Steady-state cutting

Burr initiation Plastic deformation at the center (thin) Development Plastic zone expands with little cutting Initial fracture Fracture at the edge of the drill Burr formation Burr and cap formation

Burr initiation Plastic deformation at the center (thick) Development Plastic zone expands with little cutting Initial fracture Fracture at the center of the drill Burr formation Burr and cap formation

KEY ISSUES FOR THIS PROGRAM  Material modeling under high strain dynamics  Efficient modeling technique to reduce computation time  Empirical evaluation of new tool design for burr minimization STATUS: On going REFERENCE: [1] Min, S., Dornfeld, D. A., Kim, J., Shyu, B., Finite Element Modeling of Burr Formation in Metal Cutting, International Journal of Machining Science and Technology, vol. 5, no. 3, pp. 307-322, 2001. [2] Choi, J., Min, S., Dornfeld, D. A., Alam, M., Tzong, T., Modeling of Inter-layer Gap Formation in Drilling of a Multi-layered Material, 6th CIRP International Workshop on Modeling of Machining Operations, Hamilton, Ontario, Canada, May, 2003. [3] Min, S., Modeling of Drilling Burr Formation and Development of Expert System, Ph.D. Dissertation, Department of Mechanical Engineering, University of California, CA, USA, 2001. [4] Guo, Y. B., Dornfeld, D. A., Finite Element Modeling of Drilling Burr Formation Process in Drilling 304 Stainless Steel, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 122, no. 4, pp. 612-619, 2000.

3.3.6. Thrust force analysis of drilling burr formation using finite element method
CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group conducted thrust force analysis of the drilling burr formation. A finite element model for drilling burr formation was used. A stainless steel workpiece (AISI 304L) and a conventional twist drill were used for both simulation and experiments. The thrust force variation during drilling process from FEM was obtained and compared with the experimental results. The estimation of burr size is briefly discussed. A constant thrust force was observed during steady-state cutting. As feed increases, thrust force in steady-state cutting increases and so does burr size. The burr initiation point was defined where an abrupt fluctuation in thrust force occurred when the exit surface reached its yield point, which was observed in both simulation and experiments. The burr initiation point is important because it results in different burr types. KEY ISSUES FOR THIS PROGRAM  Burr initiation point and thrust force relationship in drilling STATUS: On going REFERENCE: Min, S., Kim, J., Dornfeld, D. A., Thrust Force Analysis of Drilling Burr Formation Using Finite Element Method, Proceedings of the 10th International Conference Precision Engineering, Yokohama, Japan, pp. 169-173, 2001.

3.4. Other approaches 3.4.1. Probabilistic prediction of burr formation of carbon steel (AISI 1045) in face milling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group used Bayesian probabilistic model to supplement and update existing experimental database on face milling burrs. Face milling burrs of ductile materials such as a carbon steel (AISI 1045) exhibited three distinct burr types, uniform, wavy, and secondary burrs. It was found that the three burr types are dependent on the in-plane exit angle, undeformed chip ratio, and undeformed chip area at the exit stage of cut. The empirical equations, representing the burr transition curves from the relationship, a probabilistic model, in which the operational Bayesian modeling approach was adopted to include the empirical equations, was derived. The probabilistic model is capable of predicting burr types under given cutting conditions and updating its probability density as new data becomes available.

KEY ISSUES FOR THIS PROGRAM  Probabilistic burr prediction model for AISI 1045 carbon steel in face milling STATUS: On going REFERENCE: Ahn, S., Park, I. W., Dornfeld, D. A., Probabilistic Prediction of Burr Patterns of 1045 Carbon Steel in Face Milling, Machining Science and Technology, vol. 6, no. 2, pp. 151-170, 2002.

3.4.2. Prediction of burr size using neural networks and fuzzy logic in face milling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This study aimed to build a procedure for estimating and predicting burr size in face milling. Application of neural network and fuzzy logic techniques for burr formation modeling were analyzed to assist in the selection of optimal cutting parameters minimizing burr formation. Both neural networks and fuzzy logic were successfully applied to model burr formation in face milling. The established set of criteria allowed the comparison of both techniques according to their accuracy in model building. The simulations conducted revealed that with relatively small structures of neural nets or fuzzy logic it was possible to represent such a complicated phenomenon as the primary and secondary burr formation. Comparing the results of simulations from a model accuracy point of view, it was noted that neural networks serve as a universal technique to model burr formation, not only for one workpiece material but for the whole set of materials as well. Also, the generalization ability of both techniques allowed the reduction of the data set necessary to build a relationship between exit angle, cutting parameters and burr height. A relatively small set of data makes both modeling techniques very attractive from the practical application point of view. KEY ISSUES FOR THIS PROGRAM  Burr prediction using neural networks and fuzzy logic in face milling STATUS: On going REFERENCE: Sokolowski, A., Narayanaswami, R., Dornfeld, D. A., Prediction of Burr Size using Neural Networks and Fuzzy Logic, Proceedings of Japan-USA Symposium on Flexible Automation, ISCIE, Kobe, Japan, pp. 889-896, 1994.

3.4.3. Drilling burr control charts for stainless steel (AISI 304L) and low alloy steel (AISI 4118)
CATEGORY: Understanding of burr formation SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a control chart to understand burr formation with respect to cutting parameters. It can be used for finding optimal process parameters in consideration of burr minimization and productivity. The concept can be expanded to other related parameters such as tool geometry and workpiece material property. The chart, based on experimental data, is a tool for prediction and control of drilling burrs. Control charts for drilling burr formation for stainless (AISI 304L) and low alloy steel (AISI 4118) with a split point twist drill were developed. Burr classification was carried out based on the geometric characteristics, burr formation mechanisms, and sizes of the burrs. Two types of burrs, uniform burr (type I: small uniform burr, type II: large uniform burr) and crown burr, for stainless steel and three types of burrs, uniform burr (type I: small uniform burr, type II: large uniform burr), transient burr, and crown burr, for low alloy steel were found. New parameters consisting of process parameters and drill diameter were developed, and used to show a unique distribution of the burr types. Burr types and the resultant burr size showed great dependence on the new parameters regardless of the drill diameter. Through the chart, burr type can be predicted as a function of given cutting conditions. Also cutting conditions that are believed to create preferred burr types can be selected.

Type I uniform burr

Type II uniform burr

Type III crown burr

(a) Drilling burr control chart for AISI 304L

Type I uniform burr Type II uniform burr

Transient burr

Type III crown burr

(b) Drilling burr control chart for AISI 4118 Figure 3.4 Drilling Burr Control Chart [3] ( Fn is a non-dimensionalized feed parameter and S is a cutting speed parameter) KEY ISSUES FOR THIS PROGRAM  Drilling burr control chart for burr prediction and process planning STATUS: On going REFERENCE: [1] Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Stainless Steel, Transactions of NAMRI/ SME, vol. 28, pp. 317-322, 2000. [2] Min, S., Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Low Alloy Steel, AISI 4118, Journal of Materials Processing Technology, vol. 113, no. 1-3, pp. 4-9, 2001. [3] Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001.

4. Burr minimization and prevention

4.1. Process planning 4.1.1. Burr minimization in face milling by geometric approach
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT A strategy for minimizing two types of burrs that occur in face milling primary and secondary burr was developed. The primary burr is much larger in size compared to the secondary burr. For most precision components the primary burr needs to be removed in a deburring operation subsequent to machining. This research group developed an algorithm to minimize the length of edges of a part with a primary burr using experimental burr formation data. A representation in a CAD framework to parameterize the edges of a part into primary and secondary burr zones was developed. An objective function evaluated primary burr length, and this function was minimized with respect to the angle of approach of the cutter, cutter center position and the cutter radius. Inequality conditions were developed for identifying entry and exit regions and demarcating primary and secondary burr regions on the edges of the part. These inequality conditions lead to a fast and efficient evaluation of the objective functions. Simulation results verified that the cutter position, cutter radius and the orientation of the part are important parameters which can be carried to minimize the length of edges with a primary burr. The length was reduced by at least 30 % for most part shapes by adjusting the abovementioned parameters. KEY ISSUES FOR THIS PROGRAM  Burr minimization using optimization algorithm with experimental data in face milling STATUS: On going REFERENCE: [1] Narayanaswami, R., Dornfeld, D. A., Burr Minimization in Face Milling of Flat Polygonal Parts, ESRC Technical Report #94-23, University of California at Berkeley, October, 1994. [2] Narayanaswami, R., Dornfeld, D. A., Burr Minimization in Face Milling: A Geometric Approach, Transactions of the ASME, Journal of Manufacturing Science and Engineering, vol. 119, no. 2, pp. 170-177, 1997.

4.1.2. Multi-agent process planning for a networked machining service

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Automated process planning for machining has been a research topic for many years. However, creating a fully automated process planning module is still quite challenging, especially when multiple goals need to be achieved. This research group proposed a multi-agent process planning module in a networked machining service. The planning module incorporated i) a fundamental planning agent for achieving machining efficiency and lower cost, ii) an environmentally conscious planning agent for minimizing the energy and waste stream generation, and iii) a burr minimization planning agent for higher machining quality. The architecture of the planner module was proposed. Comparisons among the process plans generated from these different agents were conducted and the trade-offs among these plans for different goals were also investigated. KEY ISSUES FOR THIS PROGRAM  Burr minimization through agent based process planning STATUS: On going REFERENCE: [1] Dornfeld, D. A., Wright, P. K., Process Planning for Agent-based Precision Manufacturing, Transactions of NAMRI/SME, vol. 25, pp. 359-364, 1997. [2] Dornfeld, D. A., Wright, P. K., Wang, F., Sheng, P., Stori, J., Sundararajan, V., Krishnana, N., Chu, C., Multi-Agent Process Planning for a Networked Machining Service, Transactions of NAMRI/SME, vol. 27, pp. 191-196, 1999.

4.1.3. Prediction and simulation of milling burr formation for edge-precision process planning
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a burr prediction and simulation system for edge-precision process planning in planar milling. Given workpiece geometry, cutting parameters, and tool path, this system first classifies the workpiece edges according to different burr formation mechanisms obtained experimental studies. For each edge type, tool engagement conditions is computed for inquiry generation to corresponding database, in which burr type is predicted with different criteria. The location of each type of burr is graphically displayed along the workpiece edges. This project provided and based a systematic approach for the use of experimental data on milling burr formation represented in different form. Burr prediction was integrated into the process planning stage, providing effective tools that help reduce milling burr formation and deburring cost. KEY ISSUES FOR THIS PROGRAM  Edge recognition from CAD file of the workpiece  Burr prediction by tool engagement on workpiece edges STATUS: On going REFERENCE: Chu, C. H., Dornfeld, D. A., Brennum, C., Prediction and Simulation of Milling Burr Formation for Edge-Precision Process Planning, Proceedings of the 3rd International Conference on Integrated Design and Manufacturing in Mechanical Engineering, Montreal, Canada, 2000.

4.1.4. Geometric approaches for reducing burr formation in planar milling by avoiding tool exits
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group found that one of the most effective methods for reducing milling burr formation is to prevent the tool from exiting the workpiece. Exit here refers specifically to the tool cutting edges moving out of the workpiece at an edge while removing material. Under this circumstance only entrance burrs can occur, which is usually extremely small and negligible. This group designed a set of geometric algorithms for avoiding tool exits in planar milling. Two distinct approaches were developed for tool path planning of 2D polygons. The first approach generates exit-free tool paths by offsetting the workpiece edges with appropriate widths of cut. The second one locally adjusts tool positions on given tool paths. In addition, a two-stage algorithm was designed for 2D free form contours. The cutter locations that cause the tool to exit the workpiece are first detected. Then a heuristic scheme is applied to generate new cutter locations with no tool exits. Experimental results showed that edge quality were significantly improved using the proposed methods. This work provided a feasible way to minimize burr formation in an automatic manner, reducing deburring process.

Figure 4.1 Procedures of avoiding tool exits [1]

Figure 4.2 Procedures of avoiding tool exits around a vertex [1]

KEY ISSUES FOR THIS PROGRAM  Burr prevention algorithm by avoiding tool exit STATUS: On going REFERENCE: [1] Chu, C. H., Dornfeld, D. A., Tool Path Planning for Avoiding Exit Burrs, Journal of Manufacturing Processes, vol. 2, no. 2, pp.116-123, 2000. [2] Hassamontr J., Blondaz, L., Dornfeld, D. A., Avoiding Exit Burr in CNC End Milling By an Adapted Tool Path, ASME IMECE, Anaheim, CA, USA, pp. 497-501, 1998.

4.1.5. Tool path planning for exit burr minimization by estimating the total length of primary burrs
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Experimental studies show that the in-plane exit angle is a crucial factor affecting the burr formation in the face milling operation. Primary burrs are likely to form when the exit angle is larger than a threshold value, which is determined by other cutting parameters such as depth of cut and feed rate. This research group developed an algorithm for estimating the total length of primary burrs in face milling of 2D parts. Compared to previous work, this algorithm was more efficient and also applicable to multiple tool paths as well as work parts with curved edges and inner profiles. A tool path planning system was developed using this algorithm. Exit burr minimization was achieved by selecting tool feed directions and simulation of primary burr location. KEY ISSUES FOR THIS PROGRAM  Burr prevention algorithm by estimating the length of primary burrs STATUS: On going REFERENCE: Chu, C. H., Dornfeld, D. A., Tool Path Planning for Exit Burr Minimization by Estimating the Total Length of Primary Burrs, International Journal of Computer Integrated Manufacturing Systems, Submitted for publication, 2003.

4.1.6. Avoiding tool exit in planar milling by adjusting width of cut

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group found that avoiding tool exit from the workpiece prevents burr formation. One of many other algorithms to achieve this is adjusting width of cut. Tool paths were generated by offsetting the workpiece edges with appropriate widths of cut. Depending on the edge types, corresponding algorithms were designed for generation of exit-free tool paths. A tool path planner was successfully implemented with the above algorithms. Tool exits were thus completely eliminated in an automatic manner. Experimental verification showed that tool failures and burr formation were prevented where exit-free tool paths were applied.

Figure 4.3 Avoiding tool exit when a straight edge intersects a second circular edge [1] (a) The sense of the circular edge is clockwise (b) The sense of the circular edge is counter clockwise

Figure 4.4 Avoiding tool exit when a circular edge intersects a second straight edge [1] (c) The sense of the circular edge is clockwise (d) The sense of the circular edge is counter clockwise

KEY ISSUES FOR THIS PROGRAM  Burr prevention algorithm by adjusting width of cut (offset method)  Longer tool path problem STATUS: On going REFERENCE: [1] Rangarajan, A., Chu, C. H., Dornfeld, D. A., Avoiding Tool Exit in Planar Milling by Adjusting Width of Cut, Proceeding of the ASME, Manufacturing in Engineering Division, MED-vol. 11, pp. 1017-1025, 2000.

4.1.7. Burr minimization in face milling

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Kazuo Nakayama and Minoru Arai Yokohama National University, Japan ABSTRACT This research group proposed face milling burr classification along with efforts on burr minimization. The size of burr was shown to be reduced by (1) reducing the undeformed chip thickness, (2) selecting the cutting conditions so as to reduce the shear strain undergone by the chip and (3) designing the tool and workpiece geometry so as to strengthen the edge of workpiece and also to turn the direction of cutting force toward the workpiece. KEY ISSUES FOR THIS PROGRAM  Burr minimization in face milling  Classification of face milling burr STATUS: Closed REFERENCE: Nakayama K., Arai, M., Burr Formation in Metal Cutting, Annals of the CIRP, vol. 36, no. 1, pp. 3336, 1987.

4.1.8. Feature sequencing for burr minimization

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group proposed a milling burr minimization scheme using feature sequencing. Feature sequencing is a significant part of macro planning. The workpiece material properties and the nature of the metal cutting operation associated with each machining feature were assumed to be encapsulated in template files. Feature sequencing algorithms under different templates were discussed. Criteria such as ease of burr removal and edge tolerances were also incorporated via definitions of accessibility and deburr cost functions. KEY ISSUES FOR THIS PROGRAM  Burr minimization by feature sequencing STATUS: On going

4.1.9. Various methods to minimize the burr formation in milling and drilling
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Wang Guicheng Jiangsu University of Science and Technology Zhenjiang, China 212013 ABSTRACT This research group proposed several ways to minimize the burr formation in drilling and milling. Main influence factors on burrs were investigated; they were support rigidity at the end of workpiece and cutting force and its direction in metal cutting. And furthermore, use of backup material, adjustment of cutting parameters, chamfer at the end of the workpiece, selection of form of the cutting tool and other methods to control and decrease burr formation in drilling and milling process were suggested. KEY ISSUES FOR THIS PROGRAM  Burr minimization through process parameters and tool design STATUS: On going REFERENCE: Guicheng, W., Controlling Ways of the Burrs in Metal Cutting, the 1st Asia Pacific and 2nd JapanChina International Conference on Progress of Cutting and Grinding, pp. 641-646, 1994.

4.2. Tool development 4.2.1. Influence of approach angle on minimizing the burr size in metal cutting
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Tool development CONTACT INFORMATION: Rikio Hikiji Department of Mechanical Engineering Kagoshima National College of Technology 1460-1 Shinko, Hayato-cho, Aira-gun Kagoshima 899-51, JAPAN hikiji@kagoshima-ct.ac.jp http://www.kagoshima-ct.ac.jp/dps/mech/hikiji/hikiji.html ABSTRACT This research group proposed burr minimization by optimal value of the approach angle in metal cutting. The approach angle of the cutting tool influenced remarkably the burr size. The effects of the approach angle on the burr root thickness were investigated experimentally, and as a result, the new geometry of the cutting tool edge was proposed for burr minimization. The following results were obtained: (1) when the approach angle was 80 or more, the burr root thickness decreased remarkably with the approach angle increasing in general metal cutting, (2) the finishing edge with the large approach angle decreased the burr root thickness remarkably, (3) the angle and length of finishing edges made as small as possible were more useful for controlling the generation of burr, and (4) the drill with finishing edges was efficient in making the burr root thickness as small as possible. KEY ISSUES FOR THIS PROGRAM  Tool design using approach angle concept on burr minimization STATUS: On going REFERENCE: Hikiji, R., Arai, M., Kondo, E., Kawagoishi, N., A Study on Control for the Diminution of the Size of Burr in Metal Cutting, International Journal of Japan Society of Precision Engineering, vol. 31, no. 4, pp. 293-298, 1997.

4.2.2. Development of the drill attachment for drilling burr minimization

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Tool development CONTACT INFORMATION: S. S. Pande, H. P. Relekar Department of Mechanical Engineering Indian Institute of Technology, Bombay Powai, Mumbai 400076, India ABSTRACT This research group developed a drill attachment which exerted gradual feed of the drill on reducing burr formation while drilling through-holes in metals. Experiments were planned based on response surface methodology (RSM) technique. Mathematical models correlating response parameters (burr sizes) to the process parameters, e.g. feed, hole size and workpiece hardness were obtained. Optimal process conditions to minimize the sizes of burr at the entry and exit of holes were identified. In addition an attachment was designed and developed to provide continuous modification of feed during drilling. It was found that the optimal process conditions and the use of attachment produced significant reductions in the sizes of burr. KEY ISSUES FOR THIS PROGRAM  Drilling burr minimization using feed variable drill attachment STATUS: Closed REFERENCE: Pande, S., Relekar, H., Investigations on reducing Burr Formation in Drilling, International Journal of Machine Tool Design and Research, vol. 26, no. 3, pp. 339-348, 1986.

4.3. Alternative processes 4.3.1. Low frequency vibratory drilling for burr minimization
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Alternative processes CONTACT INFORMATION: Professor Katsushige Adachi Osaka Industrial University 3-1-1, Nakagaito, Daito Osaka 674, Japan ABSTRACT This research group investigated the low frequency vibratory drilling method to minimize the burr formation. Effects of the cutting conditions and cutting force on burr shape during this drilling were examined and compared with those during the conventional drilling. It was found that the application of this method for drilling of aluminum would be effective to reduce burr formation. In case of carbon steel, the effect of this method was minimal. Using this method, the burr size was not influenced by the number of holes drilled while the burr size increased with conventional drilling. KEY ISSUES FOR THIS PROGRAM  Low frequency vibratory drilling for burr minimization STATUS: On going REFERENCE: [1] Adachi, K., Arai, N., Okita, K., Wakisaka, S., Kuratani, F., Study on Burr in Low Frequency Vibratory Drilling Proceedings of the 5th International Conference on Production Engineering. Tokyo, Japan, pp.246-151, 1984. [2] Adachi, K., Arai, N., Harada, S., Okita, K., Wakisaka, S., A Study on Burr in Low Frequency Vibratory Drilling Drilling of Aluminum, Bulletin of the Japan Society of Precision Engineering, vol. 21, no. 4, pp. 258-264, 1987.

4.3.2. Burrless drilling by ultrasonic vibration

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Alternative processes CONTACT INFORMATION: H. Takeyama Kanagawa Institute of Technology Kanagawa, Japan ABSTRACT This research group developed a ultrasonic vibration drilling method in order to prevent burr, flaking, chipping, material deterioration and etc. Ultrasonic vibration was applied in the direction of the drill feed. The synergetic effect of ultrasonic vibration and newly developed radial peripheral lip drill was experimentally demonstrated to be extremely effective for preventing burrs and material deterioration at the exit of the drilled hole of aluminum and glass fiber reinforced plastics (GFRP). KEY ISSUES FOR THIS PROGRAM  Drilling burr minimization by ultrasonic vibration STATUS: Closed REFERENCE: Takeyama, H., Kato, S., Burrless Drilling by Means of Ultrasonic Vibration, CIRP Annals, vol. 40, no. 1, pp. 83-86, 1991.

4.4. Expert systems 4.4.1. Architecture for integrated design and manufacturing for burr minimization of precision mechanical components
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Expert Systems CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Four levels of integration observed in the design to fabrication cycle of precision mechanical components were proposed. Burr formation was described as a process metric to illustrate the interactions between design and manufacturing decisions on the shape and size of the burrs formed. The types of interactions observed were utilized for a discussion about the levels of integration between design and manufacturing, and for the development of integrated design software. The architecture for the core burr software was developed and the lowest level of integration was tested through the enhancement of the core software for sensor-based robotic deburring process planning. KEY ISSUES FOR THIS PROGRAM  Burr minimization strategy from design to manufacturing  Basic architecture of burr expert system STATUS: On going REFERENCE: Stein, J. M., Dornfeld, D. A., An Architecture for Integrated Design and Manufacturing of Precision Mechanical Components, Transactions of NAMRI/SME, vol. 25, pp 249-254, 1997.

4.4.2. Burr expert systems for milling and drilling

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Expert Systems CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed burr expert systems for milling and drilling. Some of features are available online. The expert systems help manufacturing engineers, product designers, process planners to select optimal conditions, design part features, and layout production lines for burr minimization and prevention. KEY ISSUES FOR THIS PROGRAM  Burr expert system STATUS: On going REFERENCE: [1] Narayanaswami, R., Dornfeld, D. A., A Burr Agent for Precision Manufacturing, ASME IMECE, San Francisco, CA, USA, MED-vol. 2-1, pp. 979-990, 1995. [2] Min, S., Modeling of Drilling Burr Formation and Development of Expert System, Ph.D. Dissertation, Department of Mechanical Engineering, University of California, CA, USA, 2001. [3] Min, S., Dornfeld, D. A., Application of Four Levels of Drilling Burr Minimization Strategies, Proceedings of the 2nd Asia-Pacific Forum on Precision Surface Finishing and Deburring Technology, Seoul, Korea, pp. 95-104, 2002.

4.5. Other approaches 4.5.1. Finite element analysis of burr minimization with a backup material in orthogonal cutting
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT In order to effectively minimize the burr size in orthogonal cutting, three cases of backup material, thick backup, thin backup, and partial backup, were examined. A backup material, whose material properties are twice as stiff (Youngs modulus) and twice as strong (yielding and ultimate strength) as those of the workpiece material, was used. It was found that the burr size can be effectively minimized when the backup material supports the workpiece only up to the predefined machined surface. The backup material should be thick enough to allow only local deformation without bending of the backup. KEY ISSUES FOR THIS PROGRAM  Burr minimization with backup material in orthogonal cutting STATUS: Closed REFERENCE: Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part II - The Influences of Exit Angle, Rake Angle, and Backup Material on Burr Formation Processes, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 229-237, 2000.

4.5.2. Finite element analysis of burr minimization with a backup material in drilling
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Using three-dimensional FE drilling models, this research group investigated two types of backup methods to minimize drilling burr formation and predict cutting forces. They accounted for temperature-mechanical coupling, automatic mesh contact with friction and material ductile failure simultaneously. Negative shear and gap formation between the part and the backup were dominant mechanisms of drilling burr formation. The use of a bushing backup having a zero clearance resulted in significantly shorter and thinner exit burrs than typical of conventional drilling methods. The use of a solid backup material was less effective in minimizing burr size superior to an unsupported exit surface. KEY ISSUES FOR THIS PROGRAM  Burr minimization with backup material (solid and bushing backup) in drilling STATUS: Closed REFERENCE: Guo, Y. B. and Dornfeld, D. A., Finite Element Analysis of Drilling Burr Minimization with a Backup Material, Transactions of NAMRI/SME, vol. 26, pp. 207-212, 1998.

4.5.3. Product design strategy for burr prevention

CATEGORY: Burr minimization and prevention SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT In many cases, it is possible to avoid the problems caused by burrs by integrating preventive actions when designing the mechanical product. This research group proposed a methodology whose aim is to compose a strategy for avoiding problems caused by machining burrs through analyses of burr formation at the design stage. KEY ISSUES FOR THIS PROGRAM  Product design guidelines for burr prevention STATUS: On going REFERENCE: [1] Narayanaswami, R., Dornfeld, D. A., Design and Process Planning Strategies for Burr Minimization and Deburring, Transactions of NAMRI/SME, vol. 28, pp.227-232, 2000, vol. 22, pp. 313-322, 1994. [2] Blondaz, L., Brissaud, D., Dornfeld, D. A., Avoiding the Need for Deburring by Analyzing Burr Formation During Product Design, Proceedings of the 2nd International Conference on Integrated Design and Manufacturing in Mechanical Engineering, Compigne, France, 1998.

5. Deburring
Deburring includes all operations which are used to remove produced burr from simple hand deburring to high tech surface finishing by NC controlled robots. As a result of years of research, vast numbers of methods have been developed. Some typical deburring methods are introduced here with some research efforts. For better description of many deburring processes, LaRoux K. Gillespies Deburring and Edge Finishing Handbook published by SME in 1999 is recommended. According to his book, those deburring operations can be classified as follows. Mechanical deburring operations x Cutting based:  Sanding  Mechanical  Cutting  Vibratory conveyor  Manual deburring  Power brushing  Mechanized cutting  Wheel blending  Edge rolling  Trimming x Mass finishing:  Barrel tumbling  Cryogenic barrel tumbling  Vibratory deburring  Cryogenic vibratory finishing  Roll flow finishing  Spindle finishing  Fluidized bed spindle finishing  Centrifugal barrel finishing  Recipro finishing  Flow finishing  Orboresonant finishing  Magnetic loose abrasive x Other:  Liquid abrasive flow  Semi-solid abrasive flow  Abrasive jet  Cryogenic abrasive jet  Water jet  Lapping  Ultrasonic slurry Thermal deburring operations  Torch or flame melting  Thermal energy method  Plasma flame  Plasma-glow deflashing  Hot wire  Resistance heating  Laser deburring  Electronic discharge machining (EDM)

Chemical deburring operations  Chemical barrel finishing  Chemical vibratory finishing  Chemical roll flow finishing  Chemical spindle finishing  Chemical centrifugal finishing  Chemical magnetic finishing  Ultrasonic (chemical)  Chemical fluidized bed  Chlorine gas deburring Electrical deburring operations  Electrochemical barrel tumbling  Electrochemical vibratory finishing  Electrochemical roll flow finishing  Electrochemical spindle finishing  Electrochemical recipro finishing  Electrochemical orboresonant finishing  Electrochemical moving electrode  Electrochemical mesh deburring  Electrochemical brush deburring  Electrochemical deburring  Electropolish deburring

5.1. Mechanical deburring 5.1.1. Barrel tumbling

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: J. D. Spencer University of Nottingham Nottingham, England ABSTRACT This research group found that barrel tumbling process was suitable for finishing stereolithography resin components with improvements in surface roughness values of 70-80% although the time to process is long. KEY ISSUES FOR THIS PROGRAM  Application of barrel tumbling on stereolithography resin components STATUS: Closed REFERENCE: Spencer, J. D., Cobb, R. C., Dickens, P. M., Surface Finishing Techniques for Rapid Prototyping, SME Technical Paper PE, pp. 1-20, 1993.

5.1.1. Barrel tumbling (Continued)

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: F. Shafer University of Stuttgart Stuttgart, Germany ABSTRACT This research group investigated how product design influences on deburring operation in manufacturing with examples of various deburring processes such as punching, electropolish deburring, vibratory and barrel tumbling deburring, abrasive jet deburring. KEY ISSUES FOR THIS PROGRAM  Investigation of relationship between design and deburring STATUS: Closed REFERENCE: Shafer, F., Product Design Influences on Deburring, SME Technical Paper MR75-483, 1975.

5.1.2. Vibratory deburring

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group analyzed the influence of burr thickness and length on vibratory deburring time. Dimensional and weight changes were recorded as were surface finish and edge radii. Quantitative approaches for defining the deburring capabilities of this process were suggested. KEY ISSUES FOR THIS PROGRAM  Efficient vibratory deburring STATUS: Closed REFERENCE: Gillespie, L. K., Quantitative Approach to Vibratory Deburring Effectiveness, SME Technical Paper, MRR75-11, 1975.

5.1.3. Recipro deburring

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: H. Kobayashi Shikishima Tipton Manufacturing Company, Japan ABSTRACT This research group developed recipro-finishing and gyro-finishing machines. Factors such as microcrystalline abrasive media, establishment of finishing conditions, success in automation and application of proper fixtures were investigated. KEY ISSUES FOR THIS PROGRAM  Development of recipro-finishing and gyro-finishing machines STATUS: Closed REFERENCE: Kobayashi, H., Kobayashi, F. Jr., Matsunaga, M., Deburring and Finishing by Recipro-finishing and Gyro-finishing Machines, SME Technical Paper, MR77-464, 1977.

5.1.4. Flow finishing

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: Toshiji Kurobe Department of Human Engineering Kanazawa University Kanazawa, Ishikawa 920-8667, Japan ABSTRACT This research group developed a high speed slurry flow finishing method for capillary with very fine holes of less than 1 mm inner diameter. This finishing method was tested to finish the inner walls of pipes. The hole diameter was only several millimeters larger than that of the capillaries. In the experiment, a stainless steel mandrel was inserted into the pipe. Such a setup made it possible for the slurry to flow at high flow rates through the narrow clearance between the inner wall of the pipe and the mandrel under a relatively low slurry injection pressure. It was found that the surface roughness of the inner wall decreases with an increasing number of slurry passes, which proves that by such a modification of the setup, the inner wall of the pipe having a relatively large hole can be finished. The raising of the flow pressure exhibits a rapid decrease in surface roughness in the early stage and a low roughness level. KEY ISSUES FOR THIS PROGRAM  Development of flow finishing machine STATUS: On going REFERENCE: Kurobe, T., Yamada, Y., Sugimori, H., High Speed Slurry Flow Finishing of the Inner Wall of a Stainless Steel Pipe, Mechanical & Corrosion Properties, Series a (Key Engineering Materials), vol. 238-239, pp. 345-348, 2003.

5.1.5. Abrasive jet deburring

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: R. Balasubramaniam Department of Mechanical Engineering Indian Institute of Technology Bombay 400 076, India ABSTRACT This research group investigated the shape of the abrasive jet machined surface. Deburring, which includes the edge conditioning/shaping, offers a potential application area for AJM. A semi-empirical equation was derived to obtain the shape of the surface generated in AJM. With the help of this equation, it was shown that the abrasive jet machined surface was reverse bell mouthed in shape with an edge radius at the entry side of the target surface. It was also observed that the entry side diameter increases with the input parameters. The effects of particle size, stand-off-distance, center line and peripheral velocities of the jet on the generated shape were also reviewed. KEY ISSUES FOR THIS PROGRAM  Modeling of abrasive jet deburring STATUS: On going REFERENCE: Balasubramaniam, R., Krishnan, J., Ramakrishnan, N., A study on the shape of the surface generated by abrasive jet machining, Journal of Materials Processing Technology,.vol. 121, no. 1, pp. 102-106, 2002. Balasubramaniam, R., Krishnan, J., Ramakrishnan, N., Investigation of AJM for deburring, Journal of Materials Processing Technology,.vol. 79, no. 1-3, pp. 52-58, 1998.

5.1.5. Abrasive jet deburring (Continued)

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: D. R. Alwerfalli Lawrence Technological University Southfield, MI, USA ABSTRACT This research group developed a mathematical model for the abrasive jet deburring process. Developed by utilizing the incomplete block design technique, the model provides the relationship between the burr removal rate and seven input variables, including pneumatic, cutting, abrasive, and material variables. The model showed that the burr removal rate increased with an increase in the air pressure, nozzle diameter, size of abrasives, abrasives mass flow rate, and/or the nozzle-tipdistance. The burr removal rate decreased with an increase in the angle of abrasives impact, and/or the hardness of the work piece material. The burr removal rate was significantly affected by the air pressure, followed by the nozzle diameter, size of the abrasive, and abrasive mass flow rate. KEY ISSUES FOR THIS PROGRAM  Modeling of abrasive jet deburring STATUS: Closed REFERENCE: Alwerfalli, D. R., Taraman, K. S., Chadda, Y. S., Burr Removal Rate Model for an Abrasive Jet Deburring Process, SME Technical Paper, MR89-441, 1989.

5.1.6. Automated deburring with a filamentary brush

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: Professor Robert J. Stango Department of Mechanical & Industrial Engineering Marquette University Haggerty Engineering 245 P.O. Box 1881 Milwaukee, Wisconsin 53201-1881 robert.stango@marquette.edu ABSTRACT This research group developed a dynamic model for removal of edge burrs with a compliant brushing tool. Description of the burr geometry was assumed to be known through on-line measurement methods such as a computer vision system in the flexible manufacturing cell. Dynamic response of the brush/workpiece system was evaluated on the basis of experimentally obtained data. Master Curves were introduced as machining descriptors which characterize the incremental burr removal performance of the brush/workpiece system leading to the development of an analytical dynamic model for orthogonal burr removal using a finite-width brushing tool. Based upon the dynamic model for material removal, a control strategy for automatic deburring was developed. A closed-form solution for transverse brush feed rate was obtained which was applicable for removal of burrs having variable height, as described by suitable geometry functions. For illustrative purposes, simulations were carried out for a straight-edge burr profile and sinusoidal burr geometry. Experimental study identified important relationships among brush feed rate, brush penetration depth, and brush rotational speed. In order to help assess the validity of the proposed analytical model and control strategy, experiments were conducted for a combination ramp/straightedge burr configuration. The results demonstrated generally good correlation between the predicted and actual profile for the edge burr. Burr was most rapidly removed by using the highest brush speed and deepest brush/workpiece penetration depth, subject to the condition that the brush fiber was not damaged. Polymer abrasive brushing tools exhibited very slow machining characteristics and must be improved in order to be used in a production environment where burr size is appreciable. Material removal characteristics of the leading and trailing edge of brushes may be a source of error which merits further investigation. KEY ISSUES FOR THIS PROGRAM  Deburring using filamentary brush STATUS: On going REFERENCE: [1] Stango, R. J., Chen, L., Cariapa, V., Automated Deburring with a Filamentary Brush: Prescribed Burr Geometry, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 3, pp. 385-392, 1999. [2] Shia, C., Stango, R. J., Heinrich, S. M.., Analysis of Contact Mechanics for Circular Filamentary Brush/Workpart System: Part I - Modeling and Formulation, Contact Problems and Surface Interactions in Manufacturing and Tribological Systems, ASME, PED, vol. 67, pp. 171179, 1993. [3] Cariapa, V., Stango, R. J., Liang, S. K., Prasad, A., Measurement and Analysis of Brushing Tool Performance Characteristics, Part 2. Contact Zone Geometry, ASME Transactions, Journal of Engineering for Industry, vol. 113, no. 3, pp. 290-296, 1991.

5.1.7. Development of deburring machines for precision parts in mass production

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: Takashi Miyatani Manufacturing Engineering Laboratory Toshiba Corporation Kawasaki, Kanagawa, Japan ABSTRACT This research group investigated several deburring methods for precision parts in mass production. Abrasive belt grinding, barrel finishing, brushing, blasting, electro-chemical deburring, and abrasive flow machining were surveyed for cylindrical precision parts. The deburring machine was designed on the principle that a cylindrical workpiece is chamfered by a couple of 45 degree inclined grinding belts. Experimental results showed that this method was very efficient in removing burrs for precision edges with high machining efficiency. Gyro finishing (barrel finishing) was found to be most effective for deburring of complicated form casings and shafts having an offset portion. Various process conditions were examined to obtain optimal conditions for precision parts. Sintering burr was effectively removed by a combination of disk cutter and brush wheel without sacrificing surface integrity. KEY ISSUES FOR THIS PROGRAM  Deburring of precision parts STATUS: On going REFERENCE: Miyatani, T., Takazawa, K., Harada, M., Newly Developed Deburring Machines for Precision Parts in Mass Production, SME Technical Paper, MR81-382, 1981.

5.1.8. Development of design rules for robot deburring

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: Yuichi Kanda Toyo University 2100 Kujirai Nakanodai Kawagoe-shi Saitama 350, Japan ABSTRACT This research group carried out a survey on state-of-the-art deburring and finishing by an industrial robot to aid further development of a deburring and finishing robot. The key technologies for deburring robot development are the optimum selection of deburring tools, force feedback control and burr recognition. For the robot deburring, abrasive grinder disc, rotary files, and water jet are widely used. Design rules for robotic deburring and finishing which are required for advanced manufacturing systems were proposed. This group also developed a micro deburring system for engineering plastics using above mentioned design rules. It is difficult to remove micro burr on edge automatically, and deburring process is often done in still consolidated work environment and automated deburring is not advanced. Engineering plastics such as polyesters have been adopted for small machine parts. the deburring of plastics is important problem at small parts manufacture. The research focused to develop micro deburring system corresponding to the complex and small parts shape by the deburring robot. KEY ISSUES FOR THIS PROGRAM  Development of design rules for robot deburring STATUS: Closed REFERENCE: Kanda, Y. Shimda, H., Micro Deburring System for Engineering Plastics(1, 2), Proceedings of the 4th International Conference on Precision Surface Finishing and Burr Technology, Badenauheimn, Germany, 1996.

5.1.9. Intelligent deburring robot based on human demonstration

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: Ken-ichiro Shimokura Human Interface Laboratories Nippon Telegraph and Telephone Corp. Yoko 180, Japan k.shimokura@lab.ntt.co.jp Sheng Liu, Research Scientist Department of Mechanical Engineering Room 3-354 Massachusetts Institute of Technology 77 Massachusetts Ave, Cambridge, MA 02139 liudynac@mit.edu ABSTRACT This research group proposed a new method for teaching a deburring robot based on demonstration of skillful human motion. The robot was programmed to adjust the tool feed rate in accordance with the varying burr characteristics, such as burr size and material properties. This dynamic change of tool feed rate is motivated by the effective human skill in performing a deburring task. The relationship between the tool feed rate and burr characteristics was obtained from human demonstration data and stored in a computer as an associative memory. This associative memory enabled the robot to select the tool feed rate that matches well with the burr characteristics. Therefore, the robot motion was always effective in removing burrs and generating a smooth finish of workpiece surface without severe tool wear. In order to identify burr characteristics, a laser displacement sensor was used for direct burr height measurement, and a deburring process model was applied for material property differentiation. The learned associative memory was stored and represented by a neural network, which was easily incorporated into robot programming. Experimental results showed that a robot can perform a deburring task in a manner similar to its human teacher. KEY ISSUES FOR THIS PROGRAM  Development of intelligent deburring robot by human demonstration STATUS: Closed REFERENCE: Shimokura, K., Liu, S., Programming Deburring Robots Based on Human Demonstration with Direct Burr Size Measurement, Proceedings of IEEE International Conference on Robotics and Automation, pp. 572-577, 1994.

5.1.10. Ultrasonic deburring

CATEGORY: Deburring SUB-CATEGORY: Mechanical deburring CONTACT INFORMATION: Professor Swee Hock Yeo Nanyang Technical University Singapore, Singapore msyzhang@ntu.edu.sg http://www.ntu.edu.sg/home/MSHYEO ABSTRACT This research group investigated ultrasonic deburring for high-strength materials with generic features that have `blind' or difficult-to-access burrs. Although some processes such as electrochemical and thermal energy deburring methods are able to perform well for this purpose, there are serious health and safety considerations. There are also other limitations such as the requirement for materials to be electrically conductive for electro-chemical methods. The ultrasonic deburring process was developed to deburr thick metallic and non-metallic burrs. The ability of ultrasound to propagate through elastic media and the fact that it does not require any tooling makes this technique very useful to treat surfaces that are generic in nature and difficult to access. KEY ISSUES FOR THIS PROGRAM  Development of ultrasonic deburring technique STATUS: On going REFERENCE: Yeo, S. H., Ngoi, B. K. A., Chua, L. Y., Ultrasonic deburring, International Journal of Advanced Manufacturing Technology, vol. 13, no. 5, pp. 333-341, 1997.

5.2. Thermal deburring 5.2.1. Laser deburring

CATEGORY: Deburring SUB-CATEGORY: Thermal deburring CONTACT INFORMATION: Professor Seoung Hwan Lee Department of Mechanical Engineering Hanyang University 1st Engineering Building 5-328 1271 Sa -1 Dong, Ansan, Kyunggi-Do 425-791, Korea sunglee@hanyang.ac.kr http://iml.hanyang.ac.kr ABSTRACT The purpose of this study was to develop effective way of automated deburring of precision components. A high power laser was proposed as a deburring tool for complex part edges and burrs. Experimental results for carbon steel and stainless steel were obtained. Also, the prediction of the heat affected zone (HAZ) and cutting profile of laser-deburred parts using finite element method was made and compared with the experimental results. An SEM was used to investigate the material property changes and cutting kerf shape after laser deburring experiments. It had been found that laser deburring provides reasonably accurate dimension and minimal size of HAZ, thus minimal material property changes. Also, the FEM analysis was able to effectively predict the important aspects of laser deburring such as cutting profiles, stress distributions near the cutting area and HAZ. KEY ISSUES FOR THIS PROGRAM  Laser deburring  Heat affected zone analysis using FEM STATUS: On going REFERENCE: Lee, S. H., Dornfeld, D. A., Precision Laser Deburring, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 123, no. 4, pp. 601-608, 2001.

5.2.1. Laser deburring (Continued)

CATEGORY: Deburring SUB-CATEGORY: Thermal deburring CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720, USA dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group used acoustic emission signals as a feedback for automated laser deburring process for precision parts. AE signals were sampled during laser machining/deburring under various experimental conditions and analyzed using several signal processing methods including AE rms and spectral analysis. The results, such as the sensitivity of AE signals to different laser cutting depths, edge detection capability and the frequency analysis showed a clear correlation between physical process parameters and the AE signals. A subsequent control strategy for deburring automation was proposed. KEY ISSUES FOR THIS PROGRAM  Laser deburring using acoustic emission sensor STATUS: Closed REFERENCE: Lee, S. H., Dornfeld, D. A., Precision Laser Deburring and Acoustic Emission Feedback, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 123, no. 2, pp. 356-364, 2001.

5.2.2. Thermal energy deburring

CATEGORY: Deburring SUB-CATEGORY: Thermal deburring CONTACT INFORMATION: Ronald A. Sonego SURF/TRAN Division Robert Bosch Corp Madison Heights, MI, USA ABSTRACT This group surveyed capabilities and limitations of the Thermal Energy Method (TEM) of Deburring. TEM Deburring consists of placing manufactured parts into a chamber, closing the chamber and then pressurizing the chamber with a fuel gas and oxygen mixture. The initial heat was supplied in the form of a spark from an ignition system. The spark causes the combustible mixture to ignite and all of the fuel gas is consumed to form a wave of 6000 degree F heat. The heat hitting both sides of the burr and flowing into it soon meets itself in the middle while attempting to flow into the main part through the root of the burr. Due to the thinness of the burr, the heat cannot flow into the main part rapidly enough to prevent the burr from reaching its automatic ignition temperature. KEY ISSUES FOR THIS PROGRAM  Survey of thermal energy deburring STATUS: On going REFERENCE: Montag, A. C., Thermal Deburring: Capabilities and Limitations, SME Technical Paper, MR76-135, 1976.

5.3. Chemical deburring 5.3.1. Development of chemical solutions for ferrous alloys
CATEGORY: Deburring SUB-CATEGORY: Chemical deburring CONTACT INFORMATION: Huixin Jiang Institute of Material Research/Engineering of Singapore Singapore 117602, Singapore ABSTRACT This group tested oxalic acid for chemical polishing solution for ferrous alloys. Using this solution, a significant improvement on polishing and deburring of carbon steel surface was accomplished due to a relatively mild but effective polishing mechanism sustained by oxalic acid. Moreover, the bathlife of such polishing solution was prolonged because the decomposition of hydrogen peroxide was effectively restrained. Skipping the use of nitric acid also avoids the release of harmful nitrogen dioxide to the environment. KEY ISSUES FOR THIS PROGRAM  Development of chemical deburring solutions for ferrous alloys STATUS: On going REFERENCE: Jiang, H., Chen, X., Hong, L., Mineral-acid-free Chemical Polishing Solutions for Ferrous Alloys, Applied Surface Science, vol. 218, no. 1-4, pp. 305-309, 2003.

5.3.2. Chemical accelerators

CATEGORY: Deburring SUB-CATEGORY: Chemical deburring CONTACT INFORMATION: W. H. Safranek Battelle Columbus Lab, Ohio, USA ABSTRACT This research group investigated chemicals that accelerate vibratory and barrel tumbling processes for zinc die castings as much as ten times. Biodegradable aliphatic acids were effective accelerators. Of these, maleic acid is the fastest and least costly. A decrease in surface roughness from about 16 to 5 micro-inches was obtained in only 10 minutes using a 5 g/l solution of maleic acid as the accelerator in a vibratory machine loaded with preformed, resin-bonded abrasive media. The use of maleic acid is expected to reduce vibratory finishing costs at least 90 percent. KEY ISSUES FOR THIS PROGRAM  Development of chemical accelerators STATUS: Closed REFERENCE: [1] Safranek, W. H., Secrest, A. C., Turn, J. C., Chemical Accelerators for Vibratory Finishing and Deburring of Zinc Die Castings, SME Technical Paper, MR MR76-832, 1976. [2] Safranek, W. H., Secrest, A. C., Turn, J. C., Chemical Accelerators for Vibratory Finishing, Manufacturing Engineering, vol. 77, no. 5, pp. 32-33, 1976.

5.3.3. Thermochemical deburring

CATEGORY: Deburring SUB-CATEGORY: Chemical deburring CONTACT INFORMATION: Hermann Mller University of Stuttgart Stuttgart, Germany ABSTRACT This research group investigated issues on thermochemical deburring. Thermochemical deburring makes it possible to remove burrs in a single chemical process during which the material particles removed are burned. Its effects on the crystalline structure, micro-hardness, and material removal were investigated on C15 steel. KEY ISSUES FOR THIS PROGRAM  Study on thermochemical deburring STATUS: Closed REFERENCE: Mller, H., Wagner, T., Thermochemisches Entgraten Gefuegeaenderung, Materialabtrag und Haertebeeinflussung. [Thermochemical Deburring: Structural Changes, Material Removal, and Effect On Hardness], WT Z Ind Fertigung, vol. 65, no. 8, pp. 473-478, 1975.

5.4. Electrical deburring 5.4.1. Electrochemical deburring

CATEGORY: Deburring SUB-CATEGORY: Chemical deburring CONTACT INFORMATION: M A E Hakim Ain Shams University Abdo Basha square Abbassia 11566, Cairo, Egypt ABSTRACT This group conducted research on design of tooling and optimal process conditions for electrochemical deburring (ECD). ECD tooling covers both the electrode and fixture required to receive, hold and locate the workpiece in a proper position with respect to the electrode and provides for fast loading and unloading of the workpiece. Shapes produced by means of the ECD process are only as good as the electrode used to produce them, so that the electrode shape and position with respect to the burr should be designed properly. Fixture materials should have sufficiently high electrical insulation and chemical resistance. The electrode material, on the other hand, should have excellent electrical and thermal conductivities, high corrosion resistance, high resistance against arcing damage and should be easy to fabricate. Some important design features of the ECD tooling required to achieve satisfactory deburring at minimum cost were proposed. KEY ISSUES FOR THIS PROGRAM  Electrochemical deburring tooling design STATUS: On going REFERENCE: Hakim, M. A. E., Mahdy, M. A. M., Sayed, M. A., ECD Tooling Design, International Journal of Materials & Product Technology, vol. 13, no. 3-6, pp. 167-183, 1998.

5.4.2. Rotolytic finishing

CATEGORY: Deburring SUB-CATEGORY: Thermal deburring CONTACT INFORMATION: Ronald A. Sonego SURF/TRAN Division Robert Bosch Corp Madison Heights, MI, USA ABSTRACT This research group investigated issues on rotolytic finishing which utilizes a combined rotary motion of a tool (cathode) and electrochemical action for burr removal, smoothing and radiussing. This process differs from conventional ECD (Electrochemical Deburring) and these differences make this process advantageous for many applications. Tool (or part) rotation, with circumferential speeds of 15 to 30 FPS, eliminate any long lasting arcing even if there is momentary contact between tool and burr. Typical successful applications include heat exchanger plates, gears, gearing cages, impellers and turbine rotors. KEY ISSUES FOR THIS PROGRAM  Survey of rotolytic finishing STATUS: Closed REFERENCE: Sonego, R. A., Rotolytic Finsihing, SME Technical Paper, MR89-115, 1989.

5.5. Other approaches 5.5.1. Burr prediction and cost function for deburring
CATEGORY: Deburring SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a deburring cost function to evaluate the deburring complexity of part designs and to assist in process planning for burr minimization. The main factors influencing deburring complexity are identified to be burr location, length of edges to be deburred, number of edges to be deburred and burr size. A destructive solid geometry (DSG) approach was used to investigate the potential for burr formation on edges of the part. Difficult to deburr features were defined in terms of an attributed adjacency graph (AAG). The effect of the choice and sequence of machining volumes on the number of edges on which burrs are formed was also demonstrated. KEY ISSUES FOR THIS PROGRAM  Deburring cost function depending on burr location, length and number of edges to be deburred STATUS: Closed REFERENCE: Narayanaswami, R., Dornfeld, D. A., Design and Process Planning Strategies for Burr Minimization and Deburring, Transactions of NAMRI/SME, vol. 28, pp.227-232, 2000, vol. 22, pp. 313-322, 1994.

5.5.2. Acoustic emission feedback for precision deburring

CATEGORY: Deburring SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT There have been efforts to automate deburring for some time. This has been done with robots carrying deburring tools and sensor feedback for tracking the edge. The deburring and chamfering of precision components is complicated by the fact that the burr may be very small (0.040mm or less) and conventional sensing techniques for burr following such as measurement of force on the deburring tool are unreliable due to low metal removal rates. Acoustic emission has been under development as a sensing technique for precision deburring feedback. This research group established the basis for use of acoustic emission in chamfering and deburring. The results of recent research to develop and evaluate a signal conditioning and control strategy for chamfering and deburring 6061-T6 aluminum were demonstrated. The results showed that the acoustic emission signal was sensitive to the area of contact between the chamfering tool and the workpiece and that a suitably conditioned AE signal can be used for input to a controller for machine control to successfully track and chamfer a skewed workpiece. Better edge tracking can be realized with advanced controller design. In addition, AE signal was able to detect contact between the tool and the workpiece. Increased range of performance can be achieved with the use of both force and AE RMS signals for very large and very small chamfer depth variations, respectively. KEY ISSUES FOR THIS PROGRAM  Acoustic emission feedback for efficient deburring STATUS: Closed REFERENCE: Dornfeld, D. A., Lisiewicz, Acoustic Emission Feedback for Precision Deburring, CIRP Annals, vol. 41, no. 1,pp. 93-96, 1992.

5.5.3. Design of an efficient deburring tool path

CATEGORY: Deburring SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group proposed a strategy to design deburring tool paths. Due to the lack of edge finishing information on a part, the process planner usually designs a deburring tool path to cover all edges with low feed rates. This is to ensure that all part edges are within tolerance. With the presence of edge finishing information, however, it is possible to design the deburring tool path to cover only certain part edges while still maintaining the tolerance requirement. The problem of planning such an efficient deburring tool path was formulated as a Traveling Salesman Problem (TSP). A few examples were used to illustrate the concept. KEY ISSUES FOR THIS PROGRAM  Development of an efficient deburring tool path STATUS: Closed REFERENCE: Hassamontr, J., Dornfeld, D. A., On Designing and Efficient Deburring Tool Path, Proceedings of Symposium on Decision making in Design and Manufacturing, ASME IMECE, Nashville, TN, USA, 1999.

5.5.4. Strategies to minimize deburring costs

CATEGORY: Deburring SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT A number of researchers have investigated burr formation mechanisms through careful observations and well thought-out experiments. The results of their studies help untangle underlying effects of key machining parameters on burr formation. However, so far, nobody has practically incorporated such knowledge into the area of economic process planning. This research group developed general strategies to minimize deburring cost. Furthermore, it establishes basic decision making tools for efficient deburring planning. The analytical tools to minimize deburring cost from process planning perspectives were investigated. In order to improve edge finishing condition, process planner may attempt to minimize the overall burr size profile, locate burrs on easy-toaccess edges, or to minimize burr size variation so that deburring can be done effectively. When the new deburring process appears more effective, the analysis tool proposed by Tipnis can be used to evaluate its capability. Its performance, in terms of actual deburring time, and cost were considered simultaneously to ensure feasibility of the new process. KEY ISSUES FOR THIS PROGRAM  Deburring cost evaluation  Economic deburring strategy STATUS: Closed REFERENCE: Hassamontr, J., Dornfeld, D. A., Strategies to Minimize Deburring Costs, Proceedings of ASME Design Engineering Technical Conference (DETC99), Las Vegas, NV, USA, DETC99- DFM8927, 1999.

5.5.5. Overview of deburring and edge finishing

CATEGORY: Deburring SUB-CATEGORY: Other approaches CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group conducted survey on various deburring technologies. The deburring methods reviewed were mass finishing processes, spindle finishing, abrasive blasting, bonded abrasive deburring (sanding), brushing, abrasive flow deburring, electro-chemical deburring, electro-polish deburring, thermal energy method deburring, mechanized cutting processes, manual deburring, sheet metal deburring, and several lesser known deburring processes. KEY ISSUES FOR THIS PROGRAM  Overview of deburring processes and related issues STATUS: On going REFERENCE: [1] Gillespie, L. K., Hand Deburring of Precision Parts, Bendix Corporation Unclassified Topical Report, BDX-613-1443, 1975. [2] Gillespie, L. K., Deburring Precision Miniature Parts, Journal of the ASPE, Precision Engineering, vol. 1, no. 4, pp. 189-198, 1979. [3] Gillespie, L. K., Deburring and Edge Finishing Handbook, SME, Dearborn, MI, USA, 1999.

6. Miscellaneous area
6.1. Micro-burrs 6.1.1. Burr formation in micro-grooving of optical components
CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Micro-groove, ranging in size from a few microns to several tens of microns, is the basic geometric shape of miniaturized/thinned optical components such as fresnel lens, lenticular lens, reflector, etc. Requirements of high precision shape/surface quality for optical parts to function as designed need such as ultra-precision machining with a single point diamond tool. It has also a unique advantage that various grooves can be made only by changing the tool geometry or the machining program. However, actual problems such as shape distortion and burr, which might be caused by high specific cutting force and ductile mold materials, is so undesirable because it absolutely degrade the performance of optical components. Many researches have been conducted about burr generation mechanism mostly in conventional machining. This research group investigated burr in a single groove, which swells up at both sides of a grove. A simplified model of the burr/shape distortion in grooving multiple micro-grooves was proposed and the effects of cutting parameters such as depth of cut, groove angle, etc. were experimentally investigated. It was found that the thrust force in micro-grooving plays a significant role in burr generation and shape distortion. Also, burr of micro-groove grew largely due to bending deformation caused by large groove angle and large depth of cut. A critical depth of cut, where an accumulated burr height was less than the projection of the accumulated depth of cut, was recommended for deburring after grooving. KEY ISSUES FOR THIS PROGRAM  Burr formation in micro-grooving STATUS: Closed REFERENCE: Ahn, J. H., Lim, H. S., Dornfeld, D. A., Burr and Shape Distortion in Micro-Grooving of Optical Components, Proceedings of ASPE, vol. 14, pp. 496-499, 1996.

6.1.2. Burr formation in micro-machining of aluminum alloy (Al 6061-T6)

CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group conducted experimental studies on micro-milling and micro-drilling in aluminum alloy (6061-T6). A range of different cutting speeds, chip loads and depths of cut using a tool of 127 diameter were considered. Drilling experiments with different feed to diameter ratios, cutting speeds and two drill diameters were conducted. The influence of the cutting parameters on burr size and burr type was observed. A comparison to burr formation in conventional machining was discussed. KEY ISSUES FOR THIS PROGRAM  Burr formation in micro-machining of aluminum alloy STATUS: On going REFERENCE: Lee, K., Stirn, B., Dornfeld, D. A., Burr Formation in Micro-machining Aluminum, 6061-T6, Proceedings of the 10th International Conference Precision Engineering, Yokohama, Japan, pp. 4751, 2001.

6.1.3. Burr formation in high speed micro-deep drilling

CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: Professor Toshimichi Moriwaki Department of Mechanical Engineering Rokkodai 1-1, Nada-Ku, Kobe 657-8501, Japan moriwaki@kobe-u.ac.jp ABSTRACT This research group conducted experimental studies on high speed micro drilling down to 0.1 mm in diameter. Two types of drilling machines were manufactured for this purpose, in one of which the workpiece was fixed vertically to the table, and in the other relative rotary motions were applied in horizontal direction to both tool and workpiece. The spindles were supported by hydrostatic air bearings and driven by air turbines. The maximum rotational speeds of the spindles were 50000 rpm. Two workpiece materials, stainless steel and brass, were tested with twist drills made of carbide K10 and high speed steel. The tool wear was measured and optimum cutting conditions were obtained for a given range of rotational speed and feed rate. The drilled holes were observed employing optical microscope and SEM. The influence of cutting fluid and the method of application on the cutting forces were examined. Recommended cutting conditions within the range tested were also proposed. The burrs were formed when drilled with worn tools. The size of burr in stainless steel was much greater than that in brass. The formation of burr was suppressed when the relative rotary motions were applied to both the drill and the workpiece employing the horizontal drilling machine. KEY ISSUES FOR THIS PROGRAM  Burr formation in micro-drilling of stainless steel and brass STATUS: Closed REFERENCE: Iwata K., Moriwaki, T., Hoshi, T., Basic Study of High Speed Micro Deep Drilling, CIRP Annals, vol. 30, no. 1, pp. 27-30, 1981.

6.1.4. Removal of burr in micro-grooves

CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: Professor Th. Shaller Karlsruhe Reseaerch Center (FZK) Central Experimental Department Hermann-von-Helmholtz-Platz 1 D-76344, Eggenstein-Leopoldshafen, Germany +49-(0)7247 82-3123 schaller@hvt.fzk.de ABSTRACT This research group machined microstructures in both brass and stainless steel workpieces by using ground hard metal micro end mills. The minimum groove width achieved was less than 50 for brass and about 100 for stainless steel. Burr formation was unavoidable during these machining processes. Burrs were removed by a subsequent diamond milling step for brass and electrochemical polishing for stainless steel. Our results represent the first step toward a microstructured, resistant, and cheap mold made of steel, which is then used for mass production of plastic microstructures.

Figure 6.1 SEM of a structure cut into stainless steel. Burr occurs at the upper groove edges. The lower groove edges are rounded because of the wear of the tool tip. [1] KEY ISSUES FOR THIS PROGRAM  Development of deburring technology for micro-grooves in stainless steel and brass STATUS: Closed REFERENCE: [1] Schaller, Th., Bohn, L., Mayer, J., Schubert, K., Microstructure Grooves with a Width of Less than 50 Pm Cut with Ground Hard Metal Micro End Mills, Precision Engineering, vol. 23, no. 4, pp. 229-235, 1999.

6.1.5. Measurement and effective deburring of micro-burrs in piercing operation

CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: Professor Sung-Lim Ko Department of Mechanical Design and Production Engineering Kon-kuk University 93-1 Mojin-dong, Kwanjin-gu Seoul 133-701, Korea slko@kkucc.konkuk.ac.kr http://www.premalab.re.kr/intro/intro.php ABSTRACT In piercing operation for small hole in very thin plate, micro-burrs were formed. The micro-burr is very difficult to remove because the thin plate is to be deformed during deburring and deteriorate accuracy. As a first step to remove the micro-burrs effectively, the burr must be measured accurately as much as possible. For most micro-burrs are so small as less than 10 , it is very difficult to measure. Several methods were reviewed to measure the micro burr formed in piercing operation from very thin plate with thickness less than 0.1 mm. Laser confocal method was successfully used for the measurement of the micro-burr in 0.07 mm thin plate. The effective deburring methods were also reviewed. Barreling, ultrasonic and chemical deburring methods were performed. KEY ISSUES FOR THIS PROGRAM  Measurement and deburring of micro-burr in thin plate piercing STATUS: On going REFERENCE: Ko, S. L., "Measurement and Effective Deburring for the Micro Burrs in Piercing Operation", International Journal of the Korean Society of Precision Engineering, vol.1, no.1, pp.152-159, 2000.

6.1.6. Molecular dynamics simulations of burr formation in nanometric cutting

CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: R. Komanduri Mechanical and Aerospace Engineering Oklahoma State University 218 Engineering North Stillwater, OK 74078, USA ABSTRACT This research group conducted molecular dynamics (MD) simulations of nanometric cutting under various cutting conditions to investigate burr formation and exit failure in metals. The effect of relative ductility of the workpiece, tool rake angle, depth of cut (1.45 3.62 nm), and external constraint at workpiece exit on the exit failure and burr formation in nanometric cutting was investigated. Two model FCC materials (one, to represent a ductile material, copper and the other, a somewhat more brittle material) were chosen by varying the appropriate Morse potential parameters in the MD simulation for the latter class. Although negative shear occurred with both cases, positive burr formation with no crack propagation into the workpiece was observed with the more ductile metal. In contrast, negative burr formation with crack propagation into the workpiece was observed with the not-so-ductile or somewhat brittle material. The burr dimensions measured at pivot initiation point were observed to be higher than the final burr dimensions. This is attributed to the rotation of the foot and the subsequent change in the pivot point as cutting progresses. The variation of the ratio of final burr dimensions was observed to match closely with the force ratio (Ft/Fc) variation with rake angle in nanometric cutting. This relationship was explained in terms of the cutting forces and the rotation of the resultant force vector with rake angle. The depth of cut was also observed to affect the mode of failure, resulting in positive or negative burr formation. As the undeformed chip thickness was increased, the resulting burr dimensions as well as the distance and depth of the initial pivoting point of the burr from the tool edge was observed to increase. The presence of external elastic constraint at exit resulted in the absence of burr formation.

(a) brittle work material

(b) ductile work material Figure 6.2 MD plots of two stages of the exit failure in nanometric cutting with no elastic constraint at the exit [1] KEY ISSUES FOR THIS PROGRAM  Burr formation in nano-cutting STATUS: Closed REFERENCE: [1] Komanduri, R., Chandrasekaran, N., Raff, L. M., MD Simulation of Exit Failure in Nanometric Cutting, Materials Science and Engineering A, vol. 311, no. 1-2, pp. 1-12, 2001.

6.2. Research Technology 6.2.1. Integration of CAD model of the drill with FEA for drilling burr simulation
CATEGORY: Miscellaneous area SUB-CATEGORY: Research technology CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT The goal of this work was to develop an integrated CAD/FEA system for drill design and drilling burr formation process. A drill CAD module was developed and integrated with the FEA model of drilling burr formation process through the CAD interface. The proposed prototype of integration system allow for rapid use of the FE model for drilling burr analysis and extract the geometrical data from the drill CAD module automatically. Modification of drill design is fast and simple. The developed prototype system demonstrates the feasibility of imbedding the drill CAD system with the FEA program. KEY ISSUES FOR THIS PROGRAM  Modeling and design of various drill types and testing their performance  CAD/FEA integration STATUS: On going REFERENCE: Guo, Y., Dornfeld, D.A., Integration of CAD of Drill with FEA of Drilling Burr Formation, Transactions of NAMRI/SME, vol. 26, pp. 201-206, 1998.

6.2.2. An analysis of the burrs in drilling precision miniature holes using Fractional Factorial Design
CATEGORY: Miscellaneous area SUB-CATEGORY: Research technology CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT A two level replicated fractional factorial design is used to investigate the effects of five factors on the exit burr thickness and height in the drilling of holes of diameter less than one millimeter in 304L stainless steel. The factors investigated are feed per revolution, cutting speed, drill pecking, drill wear and drill material. Increasing feed and cutting speed were found to increase the burr height and thickness, and the effect of increasing the feed was more pronounced at high cutting speeds. The effect of increase cutting speed effect is related to the increased cutting temperature observed in drilling holes with relatively high length to diameter ratios. Worn drills are shown to increase burr size and the variation in burr size for constant cutting conditions. Drill pecking is determined to be a stabilizing factor which increases the robustness of the burr formation process to changes in feed and cutting speed. KEY ISSUES FOR THIS PROGRAM  Burr analysis using fractional factorial design STATUS: On going REFERENCE: Stein, J. M., Dornfeld, D. A., Analysis of the Burs in Drilling Precision Miniature Holes, Proceedings of the 1995 ASME International Mechanical Engineering Congress and Exposition, San Francisco, CA, USA, vol. 2-1, pp. 127-148, 1995.

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