On Reduction of Formation of Burr in Face Milling of 45C8 Steels

Abstract

Burr is observed on a machined job attached to its edge. Problem is experienced due to the presence of burr in the production line affecting product quality and causing possible injury to an operator, and hence, a strategy for prevention or minimization of burr formation needs to be adopted. Usually, deburring is done to eliminate burrs in industry incurring additional cost. To tackle this problem, many investigations were made in the past on formation of burr and its minimization. The aim of the present work is to find out the condition to suppress burr formation effectively during face milling of 45C8 steel specimens, which are widely used in Indian Railways. First, in-plane exit angle is varied, and it shows that an in-plane exit angle of 30 reduces burr height remarkably. Next, with the provision of 15 exit edge bevel, it is noted that burr size can be reduced effectively to a negligible value by keeping an in-plane exit angle of 60 .

An investigation on formation of burrs during milling of aluminium alloy under wet condition

“…At a low in-plane exit angle, the need of backup support material is less, and therefore, the chance of burr formation is expected to be less. 1,4,15,27–29,31 Burr height observed is also expectedly low as seen in the present work at 30° in-plane exit angle. At 30° in- plane exit angle corresponding to three feed values, quite small burrs are seen in Figure 3(a), (d) and (g).…”

“…Similar observations were also reported previously. [27][28][29]31 At 30°in-plane exit angle corresponding to three feed values, quite small burrs are seen as depicted in Figure 5(a), (d) and (g). At the high in-plane exit angle of 90°, distinct saw type burrs are seen (at Figure 5(c), (f) and (i)).…”

“…23 Series of investigations on controlling milling burr were done by another group lead by Das. [24][25][26][27][28][29][30][31] They could reduce burr in 45C8 medium carbon steel, 24,29,30 EN-25 nickel-chromium alloy steel, 25,27 4600-M aluminum alloy 26 and commercial aluminium blocks 28,31 either by bevelling exit edge by 15°and/or providing in-plane exit angle of 30°or 60°. They varied cutting conditions under dry environment to find out the condition to have minimum burr height.…”

Reducing Shaping Burr by Beveling Exit Edge of 45C8 Steel

“…This might be due to less requirement of back up support material, as there was gradually decreasing need of cutting force when the tool advanced towards the exit end along the bevel. Slow gradual decrease in force might not allow change in orientation of shear plane, thereby suppressing burr formation as experienced in the previous works [21][22][23][24][25][26][30][31][32][33] reported by a research group lead by Das.…”

“…They reported that at the exit end of the work piece, a crack separates the chip along with the part of the workpiece above the negative shear, and the rest portion forms a burr. Some works were also reported for controlling the machining burr by Pekelharing [19], Sikdar [20], Saha et al [21], Saha and Das [22][23][24], Pratim and Das [25] and Saha et al [26].…”