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CONVENTIONAL MILLING
• Introduction
• Classification
• Mechanism of formation
• Effects Of Cutting Conditions On Burr
Formation
Burrs are injurious even during machining because they hit the
cutting edge and cause groove wear. This groove wear, in turn,
accelerates the burr growth
DEBURRING
The removal of burrs or deburring is often done by additional
machining with abrasive or finishing tools. While manual
deburring is a workable solution, it has several limitations. It is
tedious, time consuming and yields unpredictable and
inconsistent results. Special precautions must be taken to ensure
the safety of workers in a manual deburring cell. A manual
deburring operation can also be a bottleneck in a production
line.
• Primary burr
• Secondary burr
• Knife-type burr
• Wave-type
burr
• Curl-type burr
• Edge breakout
and
• Secondary
burr,
as shown
schematically in
figure .The first three
types of burrs can be
classified into the
primary burrs as
Kishimoto et al defined.
Knife-Type Burr :
The knife-type burr is created by the pushing out of the uncut
part, AB, near the transition machined surface when ψ reaches
150, as shown in Figure below The burr height (h) is about the
same as the depth of cut, d. The burr is formed by the plastic
bending moment, Mf, which is caused by the feed force Ff,
exerted on AB as the cutter advances. Photo of the knife-type
burr is shown in
Curl-Type Burrs:
For in-plane exit angles less than 45, curl-type burrs are
found after machining, as shown in figure below .A roll-over burr
along the edge KJ is created after the tool exits from the
transition machined
surface. This roll-over burr curls up as a result of the next tool
passage due to rubbing The burr along KJ is then bent and
compressed to the edge KL. The burr height is reduced
because of the curl-up. However, the burr root thickness, hr,
is larger than those of knife-type burrs. Photo of the curl-type
burr is shown in Figure below. In plane exit angles less than
90 are not suggested in real applications since the cutter
center is outside the work piece and the material removal rate
is low in this case.
Edge Breakout
Burr: The edge breakout, as shown in Figure is found when
the metal removal rate
becomes very high. A rough
chamfer and sharp burrs are
then created along the tool
exit edge. The interval of the
sharp burrs on the breakout
edge, p, is the same as the
feed rate. Photo of the edge
breakout is shown below.
Edge breakout occurred when
very high feed rate was chosen. Such high feed rate is rarely
seen in aluminum alloys under normal cutting conditions
because of the ease of machining this relatively ductile
material. Surface finish deteriorates with increasing feed rate,
and thus feed rate seldom reaches a level high enough to
cause edge breakout
• Primary burr
• Secondary burr
Primary burr is the roll-over burr produced on the tool exit edge.
The burr thickness was found to vary from minimum to
maximum burr thickness along the length of the burr.
• Introduction
• Micro Cutting And Conventional Cutting
• Classification And Mechanism of
formation
• Effects Of Cutting Conditions On Burr
Formation
INTRODUCTION
Micro-machining is the most fundamental technology for
production of miniaturized parts and components. Micro-
machining is a material removal process by means of
mechanical force. Many products have been reduced in
dimension and weight so as to increase their handiness and to
reduce their cost, such
as in the semiconductor
and biomedical fields
Micro-machining
must be precision
machining in order to
manufacture miniature
components within very
close tolerances. It
hinges on the progress
of the machine that is
able to carry out micro-
machining operations
and on the development
of micro- tools. The very
limited availability of
micro-tools is always a
major concern in micro-
machining. Unreliable
tool life and early tool
failure are the most
important problems when employing micro-tools for micro-
machining applications. In micro-machining, vibration and chip
flow characteristics are almost unnoticeable without the use of
special equipment. Micro-tools can break before the cutting edge
of the tool gets damaged
• Primary burr;
• Needle-like burr;
• Feathery burr;
• Minor burr
Fig. 10. Photos of burrs (100×) in micro-machining: (a) primary
burr; (b) needle-like burr; (c) feathery burr; (d) minor burr. N is in
rpm, S in mm/min and d in µm.
The formation process of primary burr can be illustrated in Figure
When the micro-tool fails to produce a chip after the
engagement, rubbing takes place
instead. Material ahead of the tool
path is pushed and deformed
plastically, Figure(a). Then it is
fractured near the middle, Figure(b).
The primary burr is turned over,
Figure(c) and is formed with a width
of about half of the tool diameter,
Figure(d). If fracture occurs in the
primary burr during the micro-
machining process, feathery burr or
needle-like burr is formed.
Minor burr is created when both the
axial engagement and the feed rate
are very small. d is only 1 µm and Sz
is as low as 0.025 µm for the minor
burr formation in Figure
ratio is about 1.
For this case, the rake angle becomes negative and
consequently the chip thickness increases. To investigate this
effect, three different values of ft/R were used, as shown in
Figure above. Table shows the corresponding cutting conditions
Figure (a) shows results of burr height versus feed. Feed has a
strong effect on burr height and burr height is linearly
proportional to feed. Figure (b) shows burr height as cutting
speed increases. At high feeds per tooth, 2.2 and 3.2 µm, burr
height increases as cutting speed increases.
METHODS OF CONTROL,
PREVENTION AND
REMOVAL OF BURRS
Drilling exit burr often occurs along the exit side of a hole. On
the contrary, entrance burrs are usually small and considered
burr-free. Therefore, it is beneficial to avoid design of through
holes. As shown schematically in Figure, through holes should be
replaced with blind holes for reducing exit burr when this design
change does not affect the original product function
Exit burr
Figure shows that simple counter sinks with angles greater than
90º creates an exit angle of 135º or greater . In this case, no
burrs will form at the bottom intersection for certain materials.
Hence it is favorable not to adopt 90º counter sinks in a product
design if edge quality is an important concern
Exit burr
3. Select appropriate step/slot depths
A curly side burr will form along the side edges of a slot/step
when the axial depth of cut is smaller than a critical value.
Increasing the depth of cut is likely to produce less detrimental
side burrs that loosely attach to the work part. This type of burr
is easy to remove in the deburring operation. Therefore, a
slot/step depth should be appropriately selected so that the
curly side burr will not produce
Chamfer
Macro-planning
Machining sequences determine what types of burr will form.
Each exit burr, side burr, or top burr requires different deburring
work as well as the associated deburring cost. Therefore
machining operation sequencing can be a feasible way to reduce
deburring cost. The edge-precision macro-planner contains a set
of machining feature decomposition and re-mapping rules that
result in less detrimental machining burrs.
(1) Milling prior to drilling because drilling burrs are easy to form
compared to milling burrs
1. 2.
A
(4) width first in the pocket milling for trade-offs between top
burr and exit burr formation along the island edges
3. 4.
B
Micro-planning
Cutting parameters including feed per tooth, the radial depth of
cut and the axial depth of cut are determined at the micro-
planning stage. A series of milling experiments have been
conducted for Al 6061 to select appropriate parameters. Similar
to the look-up table used in the conventional micro-planner, it is
also beneficial to set up a series of machining tables for reducing
burr formation. However, since mostly geometric factors
dominate burr formation behavior, a set of simple rules is
established from the experimental data, instead of complete
burr formation databases. These rules provide useful “handles”
for burr control in the micro-planning:
To avoid tool exits is the crucial point for reducing exit burr
formation, because tool exit is the necessary condition for exit
burr to occur. When the tool always enters the workpiece, only a
secondary burr can be produced, which is generally considered
to be burr-free.
Examples of application of burr
minimization strategies
Tool path planning in milling: One of the most successful
areas of application of burr minimization strategies is in tool
path planning for face milling. To a great extent, burr formation
in milling can be prevented by adjusting the path of the milling
cutter over the workpiece face. Specific cases have been
evaluated in automotive engine manufacturing with major
automobile companies. This can be extended to optimization of
the process to insure that surface quality, including flatness,
specifications are met or exceeded. Figure 10 shows a
conventional tool path for face milling a surface on a cast AlSi
alloy automotive engine block. The presence of substantial burrs
at critical locations required frequent tool changes as well as
additional deburring operations.
The optimized tool path using the criteria described above is
shown in Figure 11 and, in Figure 12, shows the resulting burr
free work piece. Although the tool path is substantially longer in
this example, it was possible to increase the feed rate without
loss of surface finish to maintain the required 5 second cycle
time for the process. The tool life (as a result of dramatically
reduced burr formation) was increased by a factor of 3 and the
resulting savings per machine/year were estimated at
approximately $50,000
CONTOUR CHART OF BURR FORMATION
An empirical model
described by least
squares and a contour
chart describing the
results are proposed for
use to minimize burr
formation and improve
tool life. An empirical
model of burr formation
obtained by lease
squares method is shown
below. Here, y is burr
height [µm].
Figure 12. Contour chart of burr formation.