Modeling of burr thickness in milling of ductile materials

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.…”

“…According to Ko and Lee [32], material properties had more effect on the drilling burr size than feed rate. Analytical models proposed in [27,33] were capable to predict the size and type of exit burrs in milling and drilling of ductile materials. Niknam and Songmene [27], while modeling and studying the burr formation during millings of AA6061-T6 and AA2024-T321 found that the exit burr thickness, which control the deburring difficulties and the deburring cycle time, is highly sensitive to material mechanical properties such as yield strength and to the cutting force.…”

“…(a) (b) Figure 7: (a) Pareto chart and 3D contour plot of exit up milling burr thickness of AA 6061-T6 (21) It is believed that the burr formation mechanism depends highly on the chip formation mechanism (27). Cutting forces and chip thickness h(φ) are highly affected by the feed rate, the depth of cut, and the tool and workpiece geometry.…”

“…According to (46), the variation of exit up milling burr thickness (Bt) is highly correlated with changes in tangential cutting force (Figure 8). According (46), the It is believed that the burr formation mechanism depends highly on the chip formation mechanism [27]. Cutting forces and chip thickness h(φ) are highly affected by the feed rate, the depth of cut, and the tool and workpiece geometry.…”

“…The direction and intensity of cutting forces affect the volume of the chip generated, and can also play an important role in material deformation. The influence of cutting forces on drilling and milling burr formation has been reported in [27,29,44,45]. According to [46], the variation of exit up milling burr thickness (B t ) is highly correlated with changes in tangential cutting force [ Figure 8].…”