Factors governing burr formation during high-speed slot milling of wrought aluminum alloys

Abstract

Burr formation and edge finishing are research topics with high relevance to industrial applications. To remove burrs, however, a secondary operation known as deburring is usually required. Deburring is more complex and costly when dealing with milled parts, because multiple burrs form at different locations with various sizes. Therefore, proper selection of process parameters to minimize the burr size is strongly recommended. Therefore, this requires an understanding of milling burr formation mechanism and the governing cutting parameters on milling burrs. In this article, a multilevel experimental study is arranged to investigate the effects of machining conditions, tooling and workpiece materials on burr size (height and thickness). Statistical tools are then used to determine the dominant cutting parameters on burr size and to effectively prescribe an operational window to control and minimize burr formation. It was found that optimum setting levels of process parameters to minimize each burr are different. The analysis of results shows the significant effects of cutting tool, feed per tooth and depth of cut on slot milling burrs.

Machining Burrs Formation & Deburring of Aluminium Alloys

“…The exit burr is important as it is larger in size and is most difficult to remove causing deburring problems. Therefore, many of studies paid their attention to exit burrs in drilling and milling operations [19][20][21][22][23][24][25][26][27]. Sofronas [6] summarized several factors governing drilling burr formation.…”

“…At lower speeds, the burr size observed was higher compared the one obtained at high cutting speed; this denotes a possible interaction of the feed rate and the cutting speed on burr formation. The effects of cutting parameters on top, entrance and exit burr thickness and height during the slot milling of AA 2024-T351 and AA 6061-T6 were statistically investigated in (24,25,43). Among the investigated burrs, exit up milling thickness could be controlled by cutting process parameters, such as feed per tooth, depth of cut and cutting tool (see Fig.7(a)), while other burrs, such as exit up milling burr height, are affected by the interactive effects between process parameters, but not by the direct effects of cutting parameters.…”

“…Among the investigated burrs, exit up milling thickness could be controlled by cutting process parameters, such as feed per tooth, depth of cut and cutting tool (see Fig.7(a)), while other burrs, such as exit up milling burr height, are affected by the interactive effects between process parameters, but not by the direct effects of cutting parameters. The effects of cutting parameters on top, entrance and exit burr thickness and height during the slot milling of AA 2024-T351 and AA 6061-T6 were statistically investigated in [24,25,43]. Among the investigated burrs, exit up milling thickness could be controlled by cutting process parameters, such as feed per tooth, depth of cut and cutting tool (see Fig.7(a)).…”

“…Bansal [52] found that using inserts with positive axial rake and negative radial rake angles led to satisfactory burr size and surface quality. According to [24], slot milling with a larger insert nose radius (Rε) leads to bigger exit bottom burr and smaller exit up milling side burr. In addition, when a larger Rε, pretty close to the axial depth of cut is used, a primary exit bottom burr formation is expected.…”

“…According to [42], tool coating has a negligible influence on face milling burrs. However, a certain level of coating influence on slot milling burrs was observed in [24]. According to [31,54,55], the tool condition and cutting parameters used, in particular, the feed rate, are the main governing factors affecting burr formation.…”