Strategies for Burr Minimization and Cleanability in Aerospace and Automotive Manufacturing

Avila, Miguel C.; Gardner, Joel; Reich-Weiser, Corinne; Tripathi, Shantanu; Vijayaraghavan, Athulan; Dornfeld, David

doi:10.4271/2005-01-3327

Cited by 17 publications

(8 citation statements)

References 7 publications

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“…Cleanability and burr reduction which are another green manufacturing aspects also on the machine level were studied in various machine tool researches to act as another optimization objectives in their attempts to improve machine tool performance. Example of this type of work was presented by Avila et al (2005) in the aerospace industry.…”

Section: Reducementioning

confidence: 97%

A system model for green manufacturing

Deif

2011

Journal of Cleaner Production

397

190

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a b s t r a c tManufacturing systems evolution is afunction in multiple external and internal factors. With today's global awareness of environmental risks as well as the pressing needs to compete through efficiency, manufacturing systems are evolving into a new paradigm. This paper presents a system model for the new green manufacturing paradigm. The model captures various planning activities to migrate from a less green into a greener and more eco-efficient manufacturing. The various planning stages are accompanied by the required control metrics as well as various green tools in an open mixed architecture. The system model is demonstrated by an industrial case study. The proposed model is a comprehensive qualitative answer to the question of how to design and/or improve green manufacturing systems as well as a roadmap for future quantitative research to better evaluate this new paradigm.

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Section: Reducementioning

confidence: 97%

A system model for green manufacturing

Deif

2011

Journal of Cleaner Production

397

190

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“…In one work, process control chart was made 15 for predicting burr formation and tool life, and to minimize burr size. Avila et al reported 16 a detailed recommendation on minimization of burrs in aerospace and automotive component manufacturing, whereas Chern 17 investigated on burr formation mechanisms in face milling process, and influence of cutting conditions on burr formation in three different aluminum alloys. Burr geometry was found to be strongly dependent upon in-plane exit angle.…”

Section: Introductionmentioning

confidence: 99%

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

Mandal¹,

Das

Saha

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Undesirable burrs are created out of a machining process. The objective of the present work is to explore the suitable condition to obtain no burr, or negligible burr, around the edge of a machined product at wet condition. Face milling experiments have been carried out on blocks made of aluminum alloy (Alloy-4600M) with a single, coated-carbide inserted cutter for observing the nature of burr formation. Depth of cut has been maintained constant at 3 mm for all sets of experiments. In each experiment set, three cutting velocities (170 m/min, 237 m/min and 339 m/min) and three in-plane exit angles of 30°, 60° and 90° are provided at three different feeds of 0.08 mm/tooth, 0.1 mm/tooth and 0.12 mm/tooth. First set of experiments are done without any exit edge bevel. Similar sets of experiments are carried out with 15° and 30° exit edge bevel angles to find out the condition for minimum burr. The bevel is made of a height of 3 mm. In the present experimental investigation, a minimum burr height of as low as 3 micron is obtained at an in-plane exit angle of 30° and exit edge bevel angle of 15° under the machining condition of 339 m/min cutting velocity and 0.1 mm/tooth feed.

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“…[8][9][10] By collecting the existing information about the relationship between the process parameters and burr type, drilling burr control chart, which is material specific, is utilized to decide the optimized cutting speed and feed rate for burr minimization. 4,11 These approaches have laid solid foundation for burr control. However, the interlayer gap contributes more to the interfacial burr formation than other factors, and these results make less difference to minimize the interfacial burr than expected.…”

Section: Introductionmentioning

confidence: 99%

An analytical model to predict interfacial burr height for metal stack drilling

Song

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Interfacial burrs of metal stack drilling deteriorate quality and require significant cost of time and labor to deburr. An analytical model is proposed to predict interfacial burr height in double-layered stack drilling, which can be used to control the interfacial burrs by adjusting the clamping force and pressure foot sizes. In this model, the deflections of top and bottom metal sheets are investigated under complex drilling conditions to provide an analytical model. The effect of interlayer compression was clarified and an iterative method was utilized to determine the interlayer contact region and its effect on the deflections during drilling. Experiments were conducted to drill stacked 7075T6 and 2024T3 Aluminum alloy sheets under different clamping forces. The total burr height measured from experimental results agrees well with the gap predicted by the analytical model.

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Strategies for Burr Minimization and Cleanability in Aerospace and Automotive Manufacturing

Cited by 17 publications

References 7 publications

A system model for green manufacturing

A system model for green manufacturing

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

An analytical model to predict interfacial burr height for metal stack drilling

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