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Journal articles on the topic 'Machining burrs'
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1
Kizhakken, Vipindas, and Jose Mathew. "Modeling of burr thickness in micro-end milling of Ti6Al4V." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 4 (April 28, 2018): 1087–102. http://dx.doi.org/10.1177/0954405418769916.
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Mechanical micro-machining of Ti6Al4V is finding great demand because of its wide range of application in various fields such as communication, optics and biomedical devices. Increasing demands on functioning and performance requires components to be free from burrs after the machining process. Presence of burrs on micro-mechanical parts or features significantly affects quality and proper assembly of the parts. Also in micro-machining, the size of burr is comparable to that of micro-features. Since the formation of burr is inevitable in any machining process, generally the deburring operation is performed to remove burrs. Burr thickness is one of the important parameters which describe the time and method necessary for the deburring operation. Burrs on micro-parts are generally characterized using scanning electron microscope, which is a time-consuming, costly and non-value-added activity. However, a proper mathematical model will help predict burr thickness easily. In this article, a mathematical model to predict burr thickness during micro-end milling of Ti6Al4V is presented. The proposed model was developed based on the principle of continuity of work at the transition from chip formation to burr formation. Ti6Al4V titanium alloy is one of the materials which generates segmented (saw-tooth) chips at low cutting speeds. Hence, initially an appropriate material constitutive model was selected based on better prediction of burr thickness. Then, to reduce the prediction error, machining temperature was evaluated for all experimental conditions and included in the model. From the initial study, it was found that Hyperbolic TANgent material model gives a better prediction compared to Johnson–Cook material model. Later, after including machining temperature into the model it was observed that the prediction error was reduced. The proposed model was validated with the experimental results.
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Zhu, Yun Ming, and Gui Cheng Wang. "Application and Analysis of RBF Neural Network for Burr Prediction in Micro-Machining." Applied Mechanics and Materials 37-38 (November 2010): 171–75. http://dx.doi.org/10.4028/www.scientific.net/amm.37-38.171.
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Micro-milling is widely used in material removal processes in industry. However, burrs are often formed on workpiece edges in milling process. Burr effects the dimensional tolerance and performance of the workpiece seriously and is desirable to be controlled. Burrs prediction technology is useful for cutting conditions optimization to control burrs forming. Due to lots of factors influencing the formation process of burr, it is a difficult task to establish the burr size prediction model by mathematical and mechanical method. RBF neural network was used for burr formation predition. Design of the network, network structure parameters determination and generalization capability of the network were analyzed and discussed. Achieved network has good fitting performance and generalization capability validated by experiments.
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Hashimura, M., Y. P. Chang, and David Dornfeld. "Analysis of Burr Formation Mechanism in Orthogonal Cutting." Journal of Manufacturing Science and Engineering 121, no. 1 (February 1, 1999): 1–7. http://dx.doi.org/10.1115/1.2830569.
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To prevent problems caused by burrs in machining, reduction and control of burr size is desirable. This paper presents 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 (FEM). Micro-machining tests under an optical microscope and a scanning electron microscope using Al-2024-O material were also done 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 the 2024 material and observation of the deformation at the workpiece edge in the micro-machining tests 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.
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Zhu, Yun Ming, Gui Cheng Wang, Zhi Wang, and Shu Tian Fan. "Network Database System for Metal Cutting Burr." Advanced Materials Research 24-25 (September 2007): 7–12. http://dx.doi.org/10.4028/www.scientific.net/amr.24-25.7.
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The formation and existence of burrs is one of the common phenomena in machining. It affects directly machining accuracy and parts quality. Network database system for metal cutting burr is developed using ASP.NET platform. The management of metal cutting burr data, inquiry and prediction of cutting burrs types and sizes, optimization of cutting conditions for controlling burr forming which based on the reasoning method of BP neural networks are realized. The development and realization of network database of metal cutting burr provide a convenient way for data transmission between multi-workshop and across regions, promote the development of burr controlling technology and modern manufacture technology.
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Yang, Cheng, J. Huang, W. Yue, G. F. Shi, and Gui Cheng Wang. "Prediction of Cutting-Direction Burr Height in Micro-Milling." Applied Mechanics and Materials 684 (October 2014): 131–36. http://dx.doi.org/10.4028/www.scientific.net/amm.684.131.
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Due to the high precision and strong molding capacity, micro-milling plays an important role in the field of micro-machining. The components machined in micro-machining is smaller than conventional components, and sometimes the generated burrs are as large as the feature size of components, so the study of micro burr control is very important. In the reseach, cutting-direction burrs are based on the traditional milling characteristics, also combined with the characteristics of micro-milling. The experimental data verify the correctness of the model well, so it provides theoretical guidance for the burrs control in micro-milling.
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Shen, Qin Xi, Gui Cheng Wang, Yun Ming Zhu, and Hai Jun Qu. "Transformation of Cutting Burr/Fracture in High-Speed Machining Al Alloy." Advanced Materials Research 53-54 (July 2008): 101–7. http://dx.doi.org/10.4028/www.scientific.net/amr.53-54.101.
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The metal cutting burr is one of the factors that influence the edge quality and performance of precision parts.A finite element model has been established to investigate the mechanism of burr formation and limit transformation in high-speed machining 2024Aluminum alloy .The burr/fracture formation process is simulated with elastic-plastic nonlinear element method based on ABAQUS.This paper has investigated the mechanism of burr /fracture formation and the limit transformation condition of cutting-direction burrs and fractures in high-speed machining and the limit transformation condition change with the cutting condition,which lay scientific basis of further research on cutting burrs formation and its minimization and deburring technology.
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Wang, Qing Hua, Dong Hua Deng, and Bo Huang. "Experimental Study on 3-Phase Abrasive Waterjet Deburring." Advanced Materials Research 411 (November 2011): 335–38. http://dx.doi.org/10.4028/www.scientific.net/amr.411.335.
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Burrs are unnecessary by-products produced by cutting metal in a machining process. It greatly affects product quality and assembly efficiency, and also affects product cost. Therefore, burrs must be removed and the surface quality must be maintained. Contrary to abrasive waterjet, 3-phase abrasive waterjet has same machining effect on a workpiece without an additional equipment to meet its circulatory requirement. An experiment was performed to analyze the effect of the 3-phase abrasive waterjet parameters on burr removal and surface quality.
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Jo, S. R., S. L. Ko, and Yuri M. Baron. "Effective Deburring of the Burr at Intersecting Hole by Permanent Magnet Inductor." Advanced Materials Research 24-25 (September 2007): 29–38. http://dx.doi.org/10.4028/www.scientific.net/amr.24-25.29.
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The sharp burrs produced by plastic deformation during machining of the precision components deteriorates the precision and performance of a machine. Thus, effective removal of the burrs may improve productivity and performance of the machinery. This study was conducted based on the experiment to remove fine burrs produced during machining process using the magnetic abrasive finishing method. The magnetic abrasive finishing using the abrasive feature of an abrasive and the magnetic nature of iron is an abrasive method to brush the burrs with iron powder that has a cohesive power due to the line of induction. The purpose of this study is to remove the burrs at intersecting holes which are difficult to access with tools, using the magnetic abrasive finishing method. Special tool is designed for deburring micro burr at intersecting holes. To find the proper deburring condition, gap distance, rotational speed of inductor, components of powder and effect of coolant are analyzed.
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Sun, Shu Feng, An Chen Yin, Ping Ping Wang, and Qin Dong Zhang. "Experimental Study of Micro Milling Burr Control Based on Process Parameters Optimization." Applied Mechanics and Materials 551 (May 2014): 569–73. http://dx.doi.org/10.4028/www.scientific.net/amm.551.569.
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With the development of the times, micro and small products are needed increasingly. The machining accuracy and surface quality are especially important to micro machining. However, in the micro milling, the size of the burr compared with that of the part is much greater than that of conventional milling. Moreover, it is difficult to remove micro milling burr by conventional deburring methods due to the small part size. The existence of burr will not only affect the match of parts, but also reduce the dimensional accuracy and surface quality of the work piece. Therefore, it is important to control and reduce micro-milling burr. Micro-milling experiments are carried out on the material of copper with micro-milling cutter diameter 0.5 mm. Micro grooves are milled with different cutting process parameters. The burrs generated under different conditions are analyzed using orthogonal test method. When the spindle speed and feed rate are constant, burrs increase with the increasing of cutting depth. Keeping the spindle speed and the depth of cut constant, burrs are generated increasingly with the increase of feed rate. And the decreasing of the spindle speed leads to the increase of burrs if the other parameters are constant. The experimental research provides reference for the burr control of micro-milling based on the optimization cutting process parameters.
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Zhang, Peng, Xing Yu Guo, Shao Fu Shan, and Chen Ge Wu. "Study on Vibration Grinding Deburring Finishing Process." Advanced Materials Research 211-212 (February 2011): 634–37. http://dx.doi.org/10.4028/www.scientific.net/amr.211-212.634.
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It is difficult to remove for burr, especially for micro-hole burr, so the vibration grinding process is put forward and adopted to remove burrs. The mechanism of vibration grinding deburring is analyzed, and the experiments of micro-hole deburring are done with the technology of vibration grinding. From the results of the experiments, the conclusion can be draw that this technology can remove the burrs effectively. The vibration grinding process has the features of simple process system, low cost, easy operating. The Vibration grinding process technology method can also be used to remove burrs of other machining process. It has more application value in practice.
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Zhang, Yi, Xiao Rong Chen, Hao Lin Li, Fu Sheng Tan, and Jun Fan Yan. "Research on Burrs Detection of Parts Surface Based on Threshold Segmentation." Applied Mechanics and Materials 618 (August 2014): 453–57. http://dx.doi.org/10.4028/www.scientific.net/amm.618.453.
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Mental cutting process, a widespread process in the machining, which can produce the maximum number of burrs. Burr detection and deburring are crucially important to safe reliability of parts. In order to avoid the effects of subjective factors effectively, and improve the production efficiency and production automation, we introduced the machine vision technique. According to the universal burrs produced in the cutting process, this paper principally studied the image segmentation, burrs feature extraction, the improvement of adaptability based on digital image processing. The authors conclude that the algorithm applied in this paper can detect the burrs information effectively, laid a solid foundation for automatic polishing, with the certain practical value.
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Huang, Juan, Yun Ming Zhu, Qin Feng Li, and Gui Cheng Wang. "Active Control Methods of Cutting Burr in Precision and Ultra-Precision Machining." Applied Mechanics and Materials 494-495 (February 2014): 620–23. http://dx.doi.org/10.4028/www.scientific.net/amm.494-495.620.
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The burr formation and control is one key technology of achieving precision and ultra-precision machining and automatic machining. Based on the theory of system engineering, the metal cutting burr formation, control and removal technology system are constructed in the paper. Then, the basic principles of burr control are presented. Combined with precision and ultra-precision machining and automatic machining, the active control methods and technologies of burr are presented. They are the modified design of parts structure, the option of tool geometry parameters, the adjustment of cutting data and processing technologies optimization etc. So, these methods lay a solid foundation on achieving minimum burrs.
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Liu, Zeng Wen, and Bo Huang. "Study on Burr Removal Technology of Micro-Channelsby a Micro Slurry Jet." Materials Science Forum 800-801 (July 2014): 815–19. http://dx.doi.org/10.4028/www.scientific.net/msf.800-801.815.
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Micro-channels are widely used in many fields. There are a lot of burrs in the process of micro-channel machining, which affect the performance of micro-channels. In this study, some polishing experiments are conducted for the burr removal of micro-channels by the micro slurry jet on the home made micro slurry jet machining system. The morphology and the roughness of the micro-channels are measured. The factors to influence the burr removal and the micro-channel surface quality are analyzed in order to take measures to improve the surface quality. The results show that the micro slurry jet polishing not only removes the micro channel burrs, but also improves the micro channel surface quality. It is helpful to increase the flow of medium inside micro channel.
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Narayanaswami, R., and D. Dornfeld. "Burr Minimization in Face Milling: A Geometric Approach." Journal of Manufacturing Science and Engineering 119, no. 2 (May 1, 1997): 170–77. http://dx.doi.org/10.1115/1.2831092.
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Experimental studies indicate that two types of burrs occur in face milling–primary and secondary burr, which are sensitive to the depth of cut and cutter exit angle. The primary burr is much larger in size compared to the secondary burr and needs to be removed by a deburring operation subsequent to machining, for effective performance of precision parts. In this paper we present a strategy for minimizing burrs in face milling. We develop a representation in a CAD framework to parametrize the edges of a part into primary and secondary burr zones. We present an algorithm which minimizes the primary burrs along the edges of the part, using a variety of objective functions reflective of deburring complexity. The parameters varied in the optimization process are of a geometric nature, affecting the cutter exit angle, and include cutter approach angle, cutter center position and the cutter radius.
15
Shin, Tae Hee, Seeung Yub Baek, and Eun Sang Lee. "Micro Electrochemical Polishing of TiNi Alloy for Medical Stent." Advanced Materials Research 79-82 (August 2009): 155–58. http://dx.doi.org/10.4028/www.scientific.net/amr.79-82.155.
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The medical stent is using widely for a surgical operation, because it can reduce the pain of cardiac. When it was developed initially, medical stent was made of stainless steel, however, the TiNi alloy is widely using presently instead of stainless steel. Because, TiNi alloy has not only super elasticity and Smart Material Effect (SME) but also excellent organism compatibility. For these reason, the TiNi alloy is currently highlighted for medical stent material better than other materials. Nevertheless, this TiNi alloy is not suitable to traditional machining process. When the traditional machining process is conducted to the TiNi alloy, it cannot be discharged the machining heat and inner stress. Also, traditional machining process makes a lot of microscopic burrs on the TiNi alloy surface. This microscopic burrs and the rough surface makes injury on vascular, so, it should be necessary non-traditional machining process without defect of traditional machining. In this paper, microscopic burrs on TiNi alloy for medical stent are removed, and surface roughness of the medical stent is evaluated by Electrochemical Polishing (EP) which is one of the non-traditional machining.
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Huang, Juan, Yong Hua Xiong, Jin Gui Huang, and Gui Cheng Wang. "Finite Element Analysis of Burr Formation in Micro-Machining." Applied Mechanics and Materials 487 (January 2014): 225–29. http://dx.doi.org/10.4028/www.scientific.net/amm.487.225.
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In the process of micro-cutting for the precision small parts, one of the main problems is the micro burrs. The finite element software Abaqus was used to simulate the micro-cutting process of aluminum 2024-T3. To create this model, Johnson-Cook (J-C) model was used to establish the material model, and Arbitrary Lagrangian Eulerian (ALE) method was used to separate the chip from work-piece. The contact friction models which was used between chip and tool was the modified Coulomb friction law. The formation process of micro burrs was simulated dynamically, and the effect of different cutting parameters and tool geometry parameters on burrs forming was analyzed. Furthermore, the general law was obtained. The results provide the guidance for optimizing the tool geometry parameters and cutting parameters to reduce the burrs in micro-cutting with the high surface quality.
17
Ali, Mohammad Yeakub, Farhana Sulaiman, Asfana Banu, Mohamed Abdul Rahman, and Muataz Hazza Faizi Al Hazza. "Investigation of Accuracy in Microdrilling with Minimum Quantity Lubrication." Materials Science Forum 882 (January 2017): 3–7. http://dx.doi.org/10.4028/www.scientific.net/msf.882.3.
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Cutting fluid plays an important role in machining processes to achieve dimensional accuracy, reduce tool wear, and improve tool life. Use of flood cooling conventionally used in machining is not cost effective and consumption of huge amount of cutting fluids is not health and environmental friendly. Therefore, one of the alternatives is to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. Study of the effects of MQL on burrs and aspect ratio should be carried out because burrs and aspect ratio are important issues in microdrilled parts used as microfluidic channels in bio-medical applications. In case of micromachining, flood cooling is not recommended to avoid any possible damage of the microstructures. As a result alternative solutions are sought. This paper investigates and compares burrs and aspect ratio in dry microdrilling and microdrilling with the presence of MQL on aluminium alloy 1100. The relationship among tool diameter, feed rate, and spindle speed on the area affected by burrs and drilled hole aspect ratio are analysed. The values of aspect ratio for both conditions show that there is slight improvement on aspect ratio in MQL over dry drilling. MQL has significant influence on affected area by burrs. It is observed that low spindle speed, high feed rate, and bigger drill diameter should be used along with MQL to reduce burrs.
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Sreenivasulu, Reddy, and Chalamalasetti SrinivasaRao. "Review on Investigations Carried out on Burr Formation in Drilling During 1975 To 2020." Technological Engineering 16, no. 1 (October 1, 2019): 43–57. http://dx.doi.org/10.1515/teen-2019-0007.
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Abstract Burr formation during machining process is a vital role in the assembly lines, even though it is a non value added process but also care should be taken while machining due to non avoiding output generated at the end of material removal process. At present almost all manufacturing sectors faces lot of problems due to these issues and invest more money towards deburring still advanced manufacturing methods available. So, complete burr removal is not possible and only thing is reducing utmost by applying better optimizing techniques, to develop good mechanization methods, selecting optimum process parameters and their conditions. The aim this paper deals about research methods implemented by earlier authors on burr formation especially in drilling. The reason why the present authors selected the drilling is number of automotive and aircraft engineers struggling during structural building works because of these burrs wherever precise measurement needed. In this connection, the authors concentrate their study on previous researcher works related to investigations on experimentation, developing new theoretical mechanisms to minimize burrs, adapt a new technologies available to modify drill bit geometries such that improvement in the minimization of burrs. Finally found that research contributions by changing their drill bit geometry and cutting process parameters have been focused on utilizing the methodologies, changing time to time. In analyzing the performance characteristics with that of input process parameters, several mathematical and empirical models were developed by many researchers so far in their works. Efforts have been made in the direction of optimization of process parameters in drilling for minimizing burr size.
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Kumar, R. Rave, M. Mohamed Abdul Hafeez, K. Velmanirajan, and K. Nantha Kumar. "Investigation of Machining Parameters in CNC Turning of EN3 Low Carbon Steel Using Genetic Algorithm and Response Surface Methodology." Applied Mechanics and Materials 592-594 (July 2014): 883–87. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.883.
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Burrs are bottleneck of precision machining and automation production. Burrs are formed in every edges and faces, during the turning process, which affects the quality level of surface roughness. In this paper the experimental study of EN3 low carbon steel were carried out to minimize the surface roughness using response surface methodology and genetic algorithm. Tungsten Carbide was used as a cutting tool for this turning operation. Machined samples are examined under Scanning Electron Microscope (SEM) for burr formation. A wide variety of analysis between cutting parameters have been shown graphically. The minimization of burr was achieved and hence better surface quality was obtained by optimizing the cutting parameters like cutting speed, feed, and depth of cut, with the aid of Genetic Algorithm (GA) & Response Surface Methodology (RSM) Techniques.
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Ji, Wei, Xian Li Liu, Yi Wen Wang, Ke Qiang Li, and Fu Gang Yan. "Research of Tool Parameter Design and Improvement of PCD Drill Machining CFRP." Advanced Materials Research 500 (April 2012): 65–72. http://dx.doi.org/10.4028/www.scientific.net/amr.500.65.
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This paper presents a design idea of PCD tool drilling CFRP and analysis of experiment of two types PCD tools machining CFRP. Firstly, parameters of PCD drill including cutting edge type, clearance angle and two point angles were improved by the mean of surveying variation of axial load values and quality of CFRP hole exit. Secondly, two types of burrs were defined from aspects of burr generated mechanism by observing plenty of burr pictures. Lastly, making use ofMATLABsoftware, function between axial load and hole numbers were ensured by data fitting in tool life analysis.
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Sreenivasulu, Reddy, and Ch Srinivasa Rao. "Optimum combination of machining parameters during drilling of Aluminium 7075 alloys using Grey based Taguchi approach." Journal of Mechanical and Energy Engineering 4, no. 3 (December 10, 2020): 227–38. http://dx.doi.org/10.30464/jmee.2020.4.3.227.
Full textAbstract:
From ancient days to till today manufacturing industries, especially making of holes on the parts during drilling process for precision assembling of parts facing problems with burr formation. Drilling operation is one of the finishing operation in the production cycle, removing of burrs during drilling process is a time consuming and non-value added process to the manufacturing sector. So reducing the size of burrs is the main aim of the present study. In the present work, optimization of burr size is considered during drilling of aluminium 7075 alloy. From Grey relational grades of responses selected optimal combination of parameters to attain multiple performance characteristics of responses with a corresponding higher grey relational grade. For identifying the most significant input parameters that influence the output responses ANOVA is conducted. Finally, observations reveals that feed rate, point and clearance angles are the most influential factors on burr size and also experimental results divulge that the lower the thrust force causes to decrease the burr height. The proposed approach is helpful to the budding entrepreneurs in the related areas to select optimal combination of drilling parameters to attain multiple performance characteristics of responses especially in burr size to prevent the post finishing operations.
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Niknam, Seyed Ali, and Victor Songmene. "Burr formation and correlation with cutting force and acoustic emission signals." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 3 (August 8, 2016): 399–414. http://dx.doi.org/10.1177/0954405415590562.
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The principle objective of this work is to present a methodology to evaluate the correlation between burr size attributes (thickness and height) and information computed from acoustic emission and cutting forces signals. In the proposed methodology, cutting force and acoustic emission signals were recorded in each cutting test, and each recorded original acoustic emission signal was segmented into two sections that correspond to steady-state cutting process (cutting signal) and cutting tool exit from the work part (exit signal). The dominant acoustic emission signal parameters including AEmax and AErms were computed from each segmented acoustic emission signal. The maximum values of directional cutting forces (FX, FY and FZ) were also measured in each trial. The experimental verification was conducted on slot milling operation which has relatively more complicated burr formation mechanism than that in many other traditional machining operations. Among slot milling burrs, the top-up milling side burrs and exit burrs along up milling side were largest and thickest burrs which were studied in this work. To evaluate the correlation between signal information and burr size, the computed signal information (5 parameters) and their interaction effects (10 parameters) were used to construct the input parameters of the multiple regression fitted models. Statistical methods were then used to assess the adequacy of individual input parameters and signal information. Using the acoustic emission and cutting force signals information in the input layer of multiple regression models, a high correlation was observed between the predicted and observed values of burr size. It was exhibited that due to complex burr formation mechanism in milling operation and strong interaction effects between cutting process parameters, no systematic relationship can be formulated between the milling burrs.
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Yang, Shie Chen, Tsuo Fei Mao, Feng Che Tsai, and Hsi Chuan Huang. "Studies of Micro-Hole Burr Improvement for Aluminum Alloy Materials Using Vibrated Abrasive Grinding Machining." Key Engineering Materials 642 (April 2015): 202–6. http://dx.doi.org/10.4028/www.scientific.net/kem.642.202.
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This study investigated the removal improvement of micro burrs of aluminum alloy materials using vibrated abrasive grinding machining. The image processing technology is used to examine and quantify the micro-hole burr profiles. The experimental results show that the micro burr was uniformly removed as the workpiece is fixture with vertical direction. In addition, the burr removal improvements are effectively influenced by the flowing velocity and the vibration energy of abrasive particles. The flowing velocities are dependent on the size and gravity of the abrasives and the vibration energy is determined by the material properties and the hardness of the abrasives.
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Chen, Lienjing, Robert J. Stango, and Vikram Cariapa. "A Force-Control Model for Edge-Deburring with Filamentary Brush." Journal of Manufacturing Science and Engineering 123, no. 3 (October 1, 1999): 528–32. http://dx.doi.org/10.1115/1.1373650.
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In this paper a force-control model is developed for edge deburring with filamentary brushes. The model is based upon experimentally obtained “master curves,” that is, material removal data that corresponds to the actual machining performance of the brush/workpart system during the incremental burr removal process. This information is used in conjunction with the on-line brush machining force to compute the brush feed rate that ensures complete removal of the edge burr. Computer simulated results are reported for the removal of an edge burr having unknown variable height. The results indicate that the present force-control model can provide a straight forward approach for computing brush feed rates that lead to complete removal of edge burrs, and suggests that implementation can be carried out using a force sensor and a simple control strategy.
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Pan, Jianfeng, Kai Feng, Lihua He, Kai Zhuang, Jing Ni, and Junjie Lv. "Influence of Different Textures on Machining Performance of a Milling Tool." Advances in Materials Science and Engineering 2020 (November 25, 2020): 1–11. http://dx.doi.org/10.1155/2020/1724241.
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Milling plays a significant role in the machining of aluminum alloy parts. However, in the milling process, the material easily adheres to the tip of the milling tool due to the high ductility and thermal deformation of the aluminum alloy; the machining efficiency and quality are hard to further improve. Hence, in order to promote the machining performances, three textures (linear, wavy, and micropitted) are prepared, respectively, on rake face of milling tools using the laser processing system. Then, milling load, top-burrs, and surface quality are chosen to discuss the machining performance of textured milling tools. In particular, the top-burrs are investigated by relative area ratio of top-burrs (RARB) which is calculated from the micrograph after binarization. The obtained results evidently show that the wavy textured milling tool reduces the milling load by an amount of 10.7% compared to the nontextured milling tool. This is due to the smaller contact area that reduces the internal friction of the tool-chip contact area and thus reduces the load. And surface roughness improves by an amount of 23.8% because the wavy texture has the largest proportion of the unit area, and it can effectively improve the storage capacity of debris. Therefore, the wavy texture proposed in this research is of great reference value for the optimization of the machining performance of the milling tool.
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Kito, Takashi, Ryutaro Tanaka, Akira Hosokawa, Takashi Ueda, and Tatsuaki Furumoto. "Prevention of Burr Formation in Face Milling of Carbon Steel by Laser Hardening." Key Engineering Materials 407-408 (February 2009): 672–75. http://dx.doi.org/10.4028/www.scientific.net/kem.407-408.672.
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. Burr is formed at workpiece edge in most metal cutting process. These burrs make troubles on production lines in terms of added cost and time for deburring process. The purpose of this study is to investigate the influence of workpiece hardening on the burr formation in face milling of carbon steel AISI 1045. Before machining, laser hardening by CO2 laser is irradiated on the side face along the line where burr is expected to be formed. The laser irradiated area of carbon steel has high hardness and brittle characteristic in comparison with mother phase. In case of machining laser hardened workpiece, the burr height was smaller compared with standard steel. By controlling laser irradiation conditions, burr is not observed so that the chipping (negative burr) like chamfering is caused. From these results, it was clarified that laser hardening is effective to prevent burr formation and this technique can be applied to high efficiency processing.
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Wang, G. C., C. Y. Zhang, Y. M. Zhu, H. J. Pei, W. G. Wu, and Q. F. Li. "Formation and control of burrs in precision machining." International Journal of Computer Applications in Technology 29, no. 2/3/4 (2007): 239. http://dx.doi.org/10.1504/ijcat.2007.015272.
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Zhao, Kai, Zhenyuan Jia, Yuanyuan Gao, and Lichao Ding. "Experimental investigation and processing optimization for micro-milling of copper clad polyimide." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 4 (June 20, 2016): 670–80. http://dx.doi.org/10.1177/0954405416654186.
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Copper clad polyimide is becoming a significant raw material for the manufacturing of special circuits such as antennas. Micro-milling, which provides a direct and flexible fabrication method in three-dimensional product machining, has replaced traditional processing methods such as photolithography. However, severe burr problem which leads to serious power loss due to the skin effect is encountered because of the selection of improper machining strategies and parameters. In this study, the influence of machining strategy on burr formation is investigated at first. Then, the formation mechanism for different kinds of burrs in micro-milling of copper clad polyimide is analyzed. Furthermore, the burr height prediction model is established, and the optimized processing parameters are obtained through response surface methodology, the predicted burr height is 12 µm. At last, a verification experiment is conducted with the optimized processing parameters. The machining result shows that the optimized parameter combination contains spindle speed of 36,110 r/min, feed per tooth of 0.70 µm/z and tool diameter of 200 µm. The average burr height for verification test is 13.9 µm. Because of the instability of copper layer on copper clad polyimide, the actual burr height is slightly larger than theoretical prediction. The error between predicted value and experiment value is 15.8%. What is noticeable is that before optimization, the burr height is up to 100 µm, while after optimization, it reduces to 13.9 µm which is reduced by 86.1%. The achievements in this study are of great significance for optimizing machining parameters and improving machining quality and efficiency of copper clad polyimide, especially in antennas field.
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Shiramoto, Kazumasa, Junki Shimizu, Akiyoshi Kobayashi, and Masahiro Fujita. "A Deburring Process Performed by Underwater Shock Wave." Materials Science Forum 673 (January 2011): 271–74. http://dx.doi.org/10.4028/www.scientific.net/msf.673.271.
Full textAbstract:
A burr is most commonly created after machining operations, such as drilling. Drilling burrs, for example, are common when drilling almost any material. When burrs are broken during the operation of a machine including the parts with the created burrs, the broken piece is in fear of disturbing normal operation or damaging the parts of the machine, so that the sufficient deburring is requested because it can affect equipment performance, reliability, and durability. Several deburring method have been developed up to date. In the present report, we proposed a deburring method by means of applying underwater shock wave. The method is as follows: after all entrance of holes is closed with seal tape, the equipment is submerged, so that all passages for running fluid are filled with air. The explosive is set under water near the entrance of the main hole. As soon as the explosive is detonated, the underwater shock wave generated at the detonation point arrives at the entrance of the hole and breaks through the tape. The water flows into the hole with a high speed. The burr is broken by water hummer action of high speed. In the present investigation, the experiments of deburring are performed under some setting conditions of explosive. It is found by experimental results, that the burr is sufficiently removed with the newly proposed method. When the shock pressure is sufficiently high at the entrance of hole, the burr is broken surface is smooth as polished one. When the shock pressure is not sufficiently high, the broken surface of the burr is notched.
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Niknam, Seyed Ali, Azziz Tiabi, and Victor Songmene. "Burr edge occupancy: edge finishing index for milling machined parts." Transactions of the Canadian Society for Mechanical Engineering 43, no. 2 (June 1, 2019): 248–55. http://dx.doi.org/10.1139/tcsme-2018-0066.
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Machining burrs are formed at all machined workpiece edges. One useful solution to decrease machining time and cost, in particular for milling parts, is to generate machined parts edges with minimum burr. This article proposes burr edge occupancy ηs as an index to evaluate deburring difficulty and, consequently, adequate selection of suitable deburring methods. Initially the sensitivity of ηs to cutting parameters must be evaluated. We investigated the main governing factors on ηs when slot milling two types of aluminium alloys (from different families) that are used in the automotive and aerospace industries. The cutting parameters that led to edges with minimum ηs are presented. It was found that, unlike most burr size attributes, ηs is sensitive to variation of the cutting parameters used: cutting speed, family of material, and cutting tools. Lower ηs means less time and effort for deburring and edge finishing of machined parts. Furthermore, ηs measurement is more convenient than the procedures used to measure other burr size attributes, including burr height (bh) and burr thickness (bt).
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Zhang, Guan Wei, S. C. Zhang, and Yu Tian Lin. "Research on Simulation of Rotary Burrs NC Grinding." Key Engineering Materials 392-394 (October 2008): 487–92. http://dx.doi.org/10.4028/www.scientific.net/kem.392-394.487.
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A 3D rotary burrs grinding simulation system is described. By analyzing the structure of rotary burrs 4-axis NC grinding machine tool, rotary burrs grinding motion model is established. The method of axis direction decomposition based on 3D modeling is provided, which includes decomposing rotational part into simple primitive cells by using Visual C++ and OpenGL as the developing tools, and implementing the boolean operation between the part model and a tool sweeping solid dependent on the tool shape and tool trajectory for each tool movement. To use grinding machining simulation analysis of the interference resulted in grinding, main factors range is determined. Security region is identified in order to avoid interference between grinding wheel and the tooth surface, which can be used for guiding production of rotary burrs and improving the quality of grinding.
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Li, Yu Chao, Zhan Qiang Liu, Yu Kui Cai, and Zhao Jun Kou. "Optimization of Cutting Parameters and Burrs Control with PMMA Coating in Micro-Milling Titanium Alloys." Materials Science Forum 836-837 (January 2016): 191–97. http://dx.doi.org/10.4028/www.scientific.net/msf.836-837.191.
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Fabrication of microchannels on titanium alloy with micro-milling is a tough challenge due to the difficultly to remove the burrs formed in machining process. A novel method to gelatinize workpiece surface to control the generation of burr as well as the optimization of cutting parameters are investigated in this paper. Differences existed between the process of micro-milling and that of traditional milling can be accounted for size effect. Influences of feed per tooth, depth of cut and spindle speed on the formation of burr were taken into consideration respectively by single factor method. The topographies of the machined surface with micro-milling were observed and measured by optical microscope. Results showed that the dimensions of burrs increased with the rise of depth of cut. However, it decreased initially, then increased later with the augment of feed per tooth. Sacrifice layer with PMMA was coated and gelatinized on the workpiece surface, which could restrain the plastic deformation of materials during titanium alloy micro-milling. The experimental results presented that the dimensions of burr could reduce greatly by the proposed PMMA coating method compared to materials without coating.
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Muto, Fumiya, Toshiki Hirogaki, Eiichi Aoyama, Tatsuya Furuki, Kiyofumi Inaba, and Kazuna Fujiwara. "Development of a Forward-Reverse Rotating cBN Electroplated End Mill Type Tool for Cutting and Grinding CFRP." International Journal of Automation Technology 15, no. 1 (January 5, 2021): 41–48. http://dx.doi.org/10.20965/ijat.2021.p0041.
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Currently, the demand for carbon fiber reinforced plastic (CFRP) has increased in various fields. However, there have been few studies investigating the machined surface quality, degradation in CFRP mechanical properties with machining temperature, or machining tool cost. In particular, the machining temperature is considered to affect the machined quality because the CFRP matrix is a resin. In this study, a cubic boron nitride (cBN) electroplated end mill was developed; this novel tool can switch between cutting and grinding without needing to change the tool. To observe the relationship between the amount of abrasive grain in contact with the CFRP and the occurrence of burrs, a grinding test was conducted with different clearance angles of the end mill and different abrasive grain sizes. The temperature during the grinding processes was measured, and the burrs were estimated after the grinding processes. From these results, the contact amount of the abrasive grit suitable for grinding was derived.
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Wang, Gui Cheng, Chun Yan Zhang, Hong Jie Pei, Yun Ming Zhu, and Li Jie Ma. "Formation and Control of Feed Direction Burrs in Machining." Materials Science Forum 532-533 (December 2006): 580–83. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.580.
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Based on the metal cutting experiments, the forming model of feed direction burr is proposed in the paper, a physical parameter of determining the generating of typeⅠ feed direction burr — critical tool edge angle rI χ is given. And the main factors which influence rI χ are studied by the experiment, and related theory analysis is made. Furthermore, some new controlling methods and technology to restrain or decrease the feed direction burr in machining are developed.
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Saputra, Endra, Gusri Akhyar Ibrahim, Suryadiwansa Harun, Eko Agus Supriyadi, and Armulani Patihawa. "Mekanisme Pembentukan Burr pada Pemesinan Frais Mikro Ti 6Al- 4V ELI dalam Keadaan Kering." Jurnal Rekayasa Mesin 11, no. 3 (December 15, 2020): 307–12. http://dx.doi.org/10.21776/ub.jrm.2020.011.03.1.
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One of the ingredients that are popular now is titanium, but titanium is a material that is difficult to process using conventional milling machining because of the poor thermal conductivity of the material so that the high-temperature machining process produced in the cutting zone causes plastic deformation in cutting tools and increased chemical reactivity in titanium. High-speed micro-milling machining can be used for micromachining of hard metals or alloys that are difficult to achieve at low speeds. Micro milling machining in titanium material 6Al-4V ELI with variations in milling knife diameter 1 and 2 mm, spindle speed 10.000 and 15.000 rpm, feed 0,001 and 0,005 mm / rev, depth of cut 100 and 150 μm, which then do data processing using the method Taguchi full factorial and theoretical analysis. The results showed that the diameter of the tool and into the cut had the greatest effect on burr formation, the greater the diameter of the milling blade resulted in the formation of shorter and smaller burrs, the use of a 1 mm diameter milling blade and a 150 μm depth cut gave rise to long burr formations and tight, while the use of a 2 mm diameter milling blade and a cutting depth of 100 μm give rise to a short and slight burr formation.
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Stango, Robert J., Lienjing Chen, and Vikram Cariapa. "Automated Deburring with a Filamentary Brush: Prescribed Burr Geometry." Journal of Manufacturing Science and Engineering 121, no. 3 (August 1, 1999): 385–92. http://dx.doi.org/10.1115/1.2832693.
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In this paper, a dynamic model for removal of edge burrs with a compliant brushing tool is reported. Description of the burr geometry is 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 is evaluated on the basis of experimentally obtained data. Master Curves are 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 is presented for burr configurations having constant height as well as variable height. A closed-form solution for transverse brush feed rate is obtained which is applicable for removal of burrs having variable height, as described by suitable geometry functions. For illustrative purposes, simulations are carried out for a straight-edge burr profile and sinusoidal burr geometry. Results are reported which identify 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, experimental results are reported for a combination ramp/straight-edge burr configuration. The results demonstrate generally good correlation between the predicted and actual profile for the edge burr that has been machined. In addition, some important observations include; (1) burr removal is most rapidly carried out by using the highest brush speed and deepest brush/workpiece penetration depth, subject to the condition that the brush fiber is not damaged, (2) Currently available polymer abrasive brushing tools exhibit very slow machining characteristics and must be improved in order to be used in a production environment where burr size is appreciable, (3) Material removal characteristics of the leading and trailing edge of brushes may be a source of error which merits further investigation.
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Liu, Ju Dong, You Sheng Li, Guo Hong Yan, Li Kun Huang, Xiao Fan Yang, and Dong Min Yu. "Experimental Study on Surface Quality in Milling Carbon Fiber Reinforced Plastics." Key Engineering Materials 667 (October 2015): 62–67. http://dx.doi.org/10.4028/www.scientific.net/kem.667.62.
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Basing on the milling experiment of carbon fiber reinforced plastics (CFRP), the machining surface qualities of different edge shape and coated tools are researched contrastively. The results show that: when the CFRP is milled by general right-hand edge milling cutter, due to the small tool rake angle, bad tool sharpness, and carbon fibers of upper and lower surface are both subjected to upswept cutting force, the burrs appear at the upper surface of workpiece. But there is no burr at the lower surface. When the CFRP is milled by interlaced edge or herringbone edge diamond coated milling cutter, which are designed to left-hand and right-hand interlace, the carbon fiber of workpiece’s upper and lower surface are subjected to downward and upswept cutting force respectively. There is no burr at the upper and lower surface of workpiece. Compared with interlaced edge diamond coated milling cutter, herringbone edge diamond coated milling cutter is more suitable for finish machining of CFRP.
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Xue, Bo, Yongda Yan, Gaojie Ma, and Zhenjiang Hu. "Study on the machining process of micro V-shaped groove by using a revolving tip." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 232, no. 9 (April 24, 2017): 1523–37. http://dx.doi.org/10.1177/0954406217705905.
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This paper proposed a machining method for micro V-shaped grooves, which was achieved by introducing the revolving trajectory on the basis of tip scratching process. By coordinating the revolving direction and the tip orientation, four kinds of revolving scratches were developed which had the revolving radii larger than the groove depths. It was found that there were two revolving scratches among these four being able to eliminate the side burrs and produce much smaller cutting forces during machining grooves compared to the traditional scratch, respectively named as the up-milling of face-forward and the down-milling of edge-forward. By considering the tip geometry in the traditional scratching process, the burr formation has been studied which was mainly affected by the effect of chip interference and the amount of uncut chip thickness. By analyzing the machining trajectory, the undeformed chip, the machined surface and the chip morphology, the reason why the up-milling of face-forward and the down-milling of edge-forward had good performances for machining V-grooves was elucidated in detail. Meanwhile, the differences between these two revolving scratches were discussed, and their advantages and disadvantages were also given.
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Kim, Jeong-Du, and Kyung-Duk Kim. "Deburring of burrs in spring collets by abrasive flow machining." International Journal of Advanced Manufacturing Technology 24, no. 7-8 (May 12, 2004): 469–73. http://dx.doi.org/10.1007/s00170-002-1536-3.
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Inoue, Takashi, Masahiro Hagino, Kazushige Tokuno, Ryo Tsuboi, and Kei Somaya. "Machining Temperature and Accuracy of Magnesium Alloy AZ31 with Deep-Hole Small Drilling." International Journal of Automation Technology 15, no. 4 (July 5, 2021): 448–56. http://dx.doi.org/10.20965/ijat.2021.p0448.
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In recent years, magnesium-based materials have become expected to replace conventional engineering plastics as next-generation industrial materials to protect the global environment. However, in the production technology, problems of cracking and unstable accuracy in drilled hole shapes persist in plastic molding and machine tool processing; many studies have been conducted to address these problems. In dry machining ignition can be caused by the material, so wet machining is the prevalent method. However, it is necessary to establish a machining method with improved environmental parameters, considering the impact of oil mist and waste oil treatment on woks. In this study, the relationship between machining temperature and the accuracy of hole shapes in magnesium alloy AZ31 is investigated with four types of drills: high-speed steel, cemented carbide (K-Base), diamond-like carbon (DLC; K-Base), and TiN-coated cemented carbide (K-Base). The drill tip angle is set to 116°, 118°, or 120°. The work material used is the extruded AZ31 magnesium alloy. To evaluate the hole shape accuracy, squares of 80 × 80 mm are used. The cutting temperature is measured over an area of 12 × 30 mm. The work material is drilled using a dry method with a 3-mm-diameter drill having the aspect ratio (L/D) of 10. The tool protrusion length of 50 mm and cutting speed of 20 m/min are fixed, and the tool feed rate and drill step amount are changed. The experiment is repeated 3 times. The burr generated around the loophole on the back surface of the test material after the test is evaluated with a criterion burr height H of 0.02 mm. Furthermore, the average roughness (Ra) of the centerline is measured on the inner surface of the hole with a contact-type roughness meter. The results show that when using the three drill point angles of 116°, 118°, and 120° in the drill step, no burrs form at the exit of the drill hole. Carbide tools form burrs when the feed rate exceeds 30 mm/min and the step amount exceeds 20 mm. TiN tools are highly accurate up to a tip angle of 118°, while DLC tools have lower cutting forces and yield better finished surfaces than the other tools.
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Akula, Sneharika, Sadvidya N. Nayak, Gururaj Bolar, and Vishwanath Managuli. "Comparison of conventional drilling and helical milling for hole making in Ti6Al4V titanium alloy under sustainable dry condition." Manufacturing Review 8 (2021): 12. http://dx.doi.org/10.1051/mfreview/2021010.
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Hole drilling in Ti6Al4V titanium alloy is challenging due to its poor machinability resulting from high-temperature strength and low thermal conductivity. Therefore, an evaluation of the helical milling process is carried out by comparing the thrust force, surface roughness, machining temperature, burr size, and hole diametrical accuracy with the conventional drilling process. The results indicate the advantage of the helical milling in terms of the lower magnitude of thrust force. The holes generated using helical milling displayed a superior surface finish at lower axial feed conditions, while higher axial feed conditions result in chatter due to the tool deformation. Also, the absence of a heat-affected zone (HAZ) under dry helical milling conditions indicates the work surface formation without thermal damage. Besides, a significant reduction in the size of the burrs is noted during helical milling due to lower machining temperature. Analysis of the hole diameter reinforces the capability of the helical milling process for processing H7 quality holes. Consequently, helical milling can be considered a sustainable alternative to mechanical drilling, considering its ability to machine quality holes under dry machining conditions.
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Bańkowski, D., and S. Spadło. "The Aplication of Vibro – Abrasive Machining for Smoothing of Castings." Archives of Foundry Engineering 17, no. 1 (March 1, 2017): 169–73. http://dx.doi.org/10.1515/afe-2017-0031.
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Abstract The paper presents the production problems related to casting using precision casting methods. The essential adverse effect of the casting process is the presence of burrs understood as oversize material necessary to remove the next finishing operations. In addition, the surfaces of the cast often characterized by a porous structure. One of the methods to improve the smoothness of the area proposed by the authors is the use of vibro-abrasive finishing. This type of treatment is widely used in the treatment of finishing small objects as well as complex shapes. Objects in the form of casting in the first step was treated with aggressive deburring polyester matrix abrasive media. The second stage was polishing, with using smoothing porcelain media. The study evaluated the effect of vibro-abrasive machining typical cast on the basic parameters of the geometric structure of the surface. Observations using optical microscope Nicon Eclipse MA 200 compared changes in surface microstructure and the effect of deburring. Clearly we can say that vibro-abrasive machining an effective way of reducing the size of burrs, smoothing and lightening the surface of objects made by casting.
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Pischan, Matthias. "Deburring of Cross Holes in Titanium Using Industrial Robots." Advanced Materials Research 769 (September 2013): 147–54. http://dx.doi.org/10.4028/www.scientific.net/amr.769.147.
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In aircrafts, hydraulic systems control moveable parts. For example parts like the front strut or the landing flaps. These parts are usually made from aluminium or titanium. Due to an increasing number of functions these valves show an increasing number of cross holes. The production process causes burrs at the intersection of the holes. Until now these burrs cant be removed reliably by an automated process. Remaining burrs can influence dimensional tolerances and reduce the efficiency and technical lifetime of the component. In some applications cross holes are used for the lubricant and coolant supply. In this case burrs can lead to blockades of critical passages or cause turbulences in the fluid. This can lead to leakage or bursting of the valve. Hence an uncontrolled removal of the burr during operation must be avoided. The consequence of these basic conditions is a time consuming manual deburring process. An automated deburring process of cross holes with industrial robots is usually performed with flexible abrasive brushes. Alternatively processes like AFM (Abrasive Flow Machining), ECM (Electro Chemical Machining) or TEM (Thermal Energy Machining) are used. Those processes are very efficient but require specialized equipment and cleaning processes for the used chemicals and the remaining abrasive paste. So they are not suitable for the deburring of safety related parts. This paper presents an experimental based approach for the robot based deburring of cross holes using industrial robots. For the deburring of cross holes several special tools are available. This article gives a short overview over the specific advantages and disadvantages of these tools. As the investigations revealed the best results can be achieved using the so called Orbitool developed by JWDone. The Orbitool is a tungsten carbide cutter developed for the deburring of cross holes. A better control of the required dimension at the intersection compared to brushes and other deburring methods is possible. Furthermore the tool can be used on machine tools and industrial robots and is flexible to a huge variety of bore diameters. The tool mainly consists of a ball shaped carbide milling cutter with a protective disk which is made of polished steel and a shaft of tool steel. To remove the burr the tool is moved along the bore axis into the smallest of the intersecting holes until the tip of the tool is close to the intersection. Then the tool is moved in radial direction to the bore surface until the tool axis corresponds to the interpolation diameter. This causes a deflection of the tool. In this situation only the protective disk is in contact with the bore surface. While the tool rotates it is moved towards the intersection in a helical motion. When the tool tip has reached the intersection the cutting edges get in contact with intersection and the deburring process begins. After the tool has passed the whole intersection it stops its rotation and is moved to the bore hole centre and then moved out of the workpiece. This paper deals with the optimization of the deburring process. The result mainly depends on the parameters movement speed of the robot, slope of the helical movement and rotational speed of the tool. The experiments are planned using DOE (Design Of Experiment) methods. Initial values for the optimization of the movement speed were determined by grid encoder measurements. Robotic specific parameters like the number of interpolating points and the influence of the path smoothing caused by the controller were also investigated. For the analysis of the burr and the secondary burr an optical 3-D measurement system is used. The results show that with the presented approach the burrs can be reliably removed. Before the deburring process the average burr height is about 60 μm and can be reduced so that there is no secondary burr visible. The result is a chamfer between 150 μm and 85 μm that depends on the process parameters. It can be demonstrated that a chamfer that is smaller than 100 μm leads to a secondary burr. Anyway the cycle time can be reduced from about 3 minutes for manual deburring to 30 seconds using an industrial robot. Additional wear analysis show that about 200 bore holes can safely be deburred.
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Sankar, M., A. Gnanavelbabu, K. Rajkumar, and M. Mariyappan. "Electro Chemical Machining of Aluminum-Boron Carbide-Nanographite Composites." Applied Mechanics and Materials 852 (September 2016): 136–41. http://dx.doi.org/10.4028/www.scientific.net/amm.852.136.
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Non-traditional machining process had made possible the machining of hard to cut materials. Among several non-traditional processes electrochemical machining has been given attention since there occurs no burrs or tool wear. Composites with nano reinforcements had outclassed their counterparts in terms of the properties shown by the nano composites. In the present work aluminium matrix has been reinforced with boron carbide and nano graphite which is added as a solid lubricant to improve tribological properties. The composite is subjected to electrochemical machining with a view of optimizing the process parameters. The process involves introducing abrasive particles while machining which aids in machining. Optimization of process parameters was based on the response surface methodology techniques with four independent input parameters such as voltage, current, electrolytic concentration and feed rate and ECM process performance in terms of material removal rate and overcut.
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Zhang, Jingyu, Yukihiko Sakisaka, Hiroshi Ishihata, Kentaro Maruyama, Eiji Nemoto, Shigeki Chiba, Masaru Nagamine, Hiroshi Hasegawa, and Satoru Yamada. "Evaluation of Preosteoblast MC3T3-E1 Cells Cultured on a Microporous Titanium Membrane Fabricated Using a Precise Mechanical Punching Process." Materials 13, no. 22 (November 22, 2020): 5288. http://dx.doi.org/10.3390/ma13225288.
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The surface topography of Titanium (Ti) combined toughness and biocompatibility affects the attachment and migration of cells. Limited information of morphological characteristics, formed by precise machining in micron order, is currently available on the Ti that could promote osteoconduction. In the present study, a pure Ti membrane was pierced with precise 25 μm square holes at 75 μm intervals and appear burrs at the edge of aperture. We defined the surface without burrs as the “Head side” and that with burrs as the “Tail side”. The effects of the machining microtopography on the proliferation and differentiation of the preosteoblasts (MC3T3-E1 cells) were investigated. The cells were more likely to migrate to, and accumulate in, the aperture of holes on the head side, but grew uniformly regardless of holes on the tail side. The topography on the both surfaces increased osteopontin gene expression levels. Osteocalcin expression levels were higher on the head side than one on the blank scaffold and tail side (p < 0.05). The osteocalcin protein expression levels were higher on the tail side than on the head side after 21 days of cultivation, and were comparable to the proportion of the calcified area (p < 0.05). These results demonstrate the capacity of a novel microporous Ti membrane fabricated using a precise mechanical punching process to promote cell proliferation and activity.
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Xu, Longhua, Chuanzhen Huang, Rui Su, Hongtao Zhu, Hanlian Liu, Yue Liu, Chengwu Li, and Jun Wang. "Estimation of tool life and cutting burr in high speed milling of the compacted graphite iron by DE based adaptive neuro-fuzzy inference system." Mechanical Sciences 10, no. 1 (June 14, 2019): 243–54. http://dx.doi.org/10.5194/ms-10-243-2019.
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Abstract. The studies of tool life and formation of cutting burrs in roughing machining field are core issues in high speed milling of compacted graphite iron (CGI). Changing any one of the cutting parameters like cutting speed or feed rate can result in varied tool life and different height of the cutting burrs. In this work in order to study the relationship between cutting parameters and tool life and height of the cutting burrs, a new differential evolution algorithm based on adaptive neuro fuzzy inference system (DE-ANFIS) as a multi-input and multi-output (MIMO) prediction model is introduced to estimate the tool life and height of the cutting burrs. In this model, the inputs are cutting speed, feed rate and exit angle, and the outputs are tool life and height of the cutting burrs. There are 12 fuzzy rules in DE-ANFIS architecture. Gaussian membership function is adopted during the training process of the DE-ANFIS. The proposed DE-ANFIS model has been compared with PSO-ANFIS, Artificial Neural Network (ANN) and Support Vector Machines (SVM) models. To construct the predictive models, 25 cutting data were obtained through the experiments. Compared with PSO-ANFIS, ANN and SVM models, the results indicate that DE-ANFIS can provide a better prediction accuracy of tool life and height of the cutting burrs, and achieve the required product and productivity. Finally, the analysis of variance (ANOVA) shows that the cutting speed and feed rate have the most effects on the tool life and height of cutting burrs, respectively.
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Mondal, Nripen, Madhab Chandra Mandal, Bishal Dey, and Santanu Das. "Genetic algorithm-based drilling burr minimization using adaptive neuro-fuzzy inference system and support vector regression." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234, no. 5 (December 3, 2019): 956–68. http://dx.doi.org/10.1177/0954405419889183.
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Burrs are undesirable materials beyond the work piece surface during drilling or other machining processes, thus this should be as less as possible during manufacturing. The experimental study has been conducted according to the full factorial design method. A total of 27 experiments were conducted by drilling on an Aluminum 6061T6 plate by choosing three factors and three levels of process parameters like drill diameter, point angle and spindle speed. In this research article, two predictive models, namely, adaptive neuro-fuzzy inference system and support vector regression, are developed using experimental data to estimate burr height and burr thickness. Then, these predictive models have been used to find out optimum process parameters for minimum burr height and burr thickness using genetic algorithm. It has been found that both the models are able to predict burr size and thickness with good accuracy, while the adaptive neuro-fuzzy inference system performs better than support vector regression.
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Sivaraman, B., Senthil Padmavathy, P. Jothiprakash, and T. Keerthivasan. "Multi-Response Optimisation of Cutting Parameters of Wire EDM in Titanium Using Response Surface Methodology." Applied Mechanics and Materials 854 (October 2016): 93–100. http://dx.doi.org/10.4028/www.scientific.net/amm.854.93.
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This Aim of this paper is to analyse the effect of machining parameters of wire electrical discharge machining (WEDM) on workpiece material titanium, that were now widely used in many applications because of its technical benefits. Conventional method of machining the material will make the work piece to crack or flaws due to chipping, presence of burrs and cracking. Wire cut Electrical discharge machining techniques have been already tried with some other high strength materials which is complicated to cut. To prove the feasibility of machining the titanium, many experiments were carried out based on RSM. Hence by the head wire electrical discharge machining process is to be used to machining the work piece material (titanium) and the effect of various control parameters on the response parameters were analysed and optimized and the optimal combination of control parameters were found to get higher metal removal rate and surface finish using Response Surface Methodology.
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Nunobiki, Masayuki, Koichi Okuda, and Yosuke Kitsugi. "Study on On-Machine Deburring for Narrow Slits Made by Laser Cutting." Advanced Materials Research 76-78 (June 2009): 306–12. http://dx.doi.org/10.4028/www.scientific.net/amr.76-78.306.
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This paper proposed an on-machine laser deburring method for narrow slits made by laser cutting. Burrs are generally unwanted materials which remain at the cutting edge after machining operations, such as grinding, drilling, milling or turning. A cost necessary to remove burrs becomes a significant portion of the machining costs. In laser cutting, dross removal was significant problem. It is difficult to prevent completely dross from adhering in laser cutting for stainless sheets. In laser cutting for adornments, it is necessary to remove the dross and to chamfer the cutting edges in order not to injure the hand. It is difficult to remove the dross and to chamfer the edges of a narrow slit by machine work or handwork. We irradiated the defocused laser beam to the slits again for these post-processing. To control the depth and width of the removal area, we examined the relationship between the removal area and the deburring conditions. It was clarified that the width and depth of removal area can be controlled by irradiation time and energy fluence.
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Wang, Gui Cheng, Qin Xi Shen, and Yun Ming Zhu. "The Analysis of Fracture Formation on Exit Edge in Pricision Machining." Advanced Materials Research 135 (October 2010): 174–78. http://dx.doi.org/10.4028/www.scientific.net/amr.135.174.
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Burrs and fractures are two types of shapes formed on exit edges in pricision machining. They affect the quality of workpiece and the efficiency of prodcution seriously. A finite element model of fracture formation process to simulate the machining process of 2024-T3 Aluminum alloy is proposed. According to simulation results, five stages and variation of shear shain in fracture formation process are analyzed. It is found that shear strain plays an important role in fracture forming process. The method of determination of critical shear strain for fracture forming is proposed from simulation results.