Aurich / Dornfeld Burrs - Analysis, Control and Removal

Proceedings of the CIRP International Conference on Burrs, 2nd-3rd April, 2009, University of Kaiserslautern, Germany
1. Auflage 2009
ISBN: 978-3-642-00568-8
Verlag: Springer
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 254 Seiten

In many machining operations burrs cannot be avoided. They can affect the functionality and the safe handling of the workpiece in the subsequent processing, and have to be removed by a special deburring process. Toleration of burrs, which are not part of functional edges, depends on their respective shape and size. High inspection effort is necessary to guarantee the workpiece quality. Therefore, the research results on burrs, with a focus on burr analysis and control as well as on cleanability and burr removal based on the presentations held at the conference are valuable for researchers and engineers in manufacturing development.

Under the guidance of Prof. Dr.-Ing. Jan C. Aurich at the Institute for Manufacturing Technology and Production Systems individual solutions in the field of manufacturing technology are developed. His research activities cover tool development, control and simulation of machining processes in the area of manufacturing technology as well as virtual production engineering and product-service systems in the area of production systems. In the context of cooperation projects, working groups, workshops and training in direct cooperation with individual enterprises solutions in the field of technology transfer are developed for the industrial practice and business challenges. Professor David Dornfeld has been conducting research on burr formation, edge finishing and cleanability for a number of years and leads an industry consortium supporting work in this area. In addition, his laboratory specializes in research on precision manufacturing with including micromachining, chemical mechanical planarization for semiconductor manufacturing, green and sustainable manufacturing, and sensors and interoperability. He has published over 300 papers in these fields, authored several books and has seven patents based on his research work. He is a consultant on sensors, manufacturing productivity and automation and process modeling and the associated intellectual property issues.

Autoren/Hrsg.

Dornfeld, David

Aurich, Jan C.

Dornfeld, David A.

Inhaltsverzeichnis

1;Preface;4
2;Contents;6
3;A Short View on CIRP;8
4;Organization;10
5;We Thank Our Sponsors;12
6;Contributors;13
7;Keynotes;17
7.1;A Review of Burr Formation in Machining;18
7.1.1;1 Introduction;18
7.1.1.1;1.1 Motivation;18
7.1.1.2;1.2 Introduction and Background;18
7.1.2;2 Process-Based Solutions;20
7.1.2.1;2.1 Introduction;20
7.1.2.2;2.2 Milling;20
7.1.2.3;2.3 Drilling;21
7.1.2.4;2.4 Grinding;22
7.1.3;3 Examples of Application of Burr Minimization Strategies;22
7.1.3.1;3.1 Tool Path Planning in Milling;22
7.1.3.2;3.2 Drilling -- Burr Control Chart;23
7.1.3.3;3.3 Burrs in Precision Machining;24
7.1.4;4 Summary and Conclusions;25
7.1.5;References;26
7.2;Burr Minimization Strategies in Machining Operations;27
7.2.1;1 Introduction;27
7.2.2;2 Burr Formation and Reduction Strategy in Turning Austenitic-Ferritic Stainless Steel;27
7.2.3;3 CO 2 -Process Cooling for Burr Reduction in Face Milling of Aluminum Alloys;29
7.2.4;4 Delamination Reduction Strategies in Machining Fiber-Reinforced Plastics;30
7.2.5;5 Burr Formation and Reduction in Machining Thin-Walled Light-Metal Frame Structures;31
7.2.6;6 Burr Formation in Micro-milling of NiTi Alloys;32
7.2.7;7 Conclusion and Outlook;34
7.2.8;References;34
7.3;Burr Formation and Avoidance for Robust Circular Blade Sawing of Thin Walled Extruded Aluminum Profiles;35
7.3.1;1 Introduction;35
7.3.1.1;1.1 Sawing Process Parameters;35
7.3.1.1.1;1.1.1 Cutting Speed;35
7.3.1.1.2;1.1.2 Rake Angle;36
7.3.1.1.3;1.1.3 Clearance Angle;36
7.3.1.1.4;1.1.4 Feed Rate per Tooth;36
7.3.1.1.5;1.1.5 Tooth Geometry;36
7.3.1.1.6;1.1.6 Machine Requirements;37
7.3.1.1.7;1.1.7 Sawing of Aluminum Profiles;37
7.3.2;2 Experimental Setup;37
7.3.2.1;2.1 Experiments;37
7.3.3;3 Results;38
7.3.3.1;3.1 Results from Experiment 1;39
7.3.3.2;3.2 Results from Experiment 2;40
7.3.3.3;3.3 Results from Experiment 3;40
7.3.4;4 Discussion of Results;41
7.3.4.1;4.1 Tooth Profile;41
7.3.4.2;4.2 Feed Rate;41
7.3.4.3;4.3 Other Process Parameters;41
7.3.4.4;4.4 Possible Sources of Errors;41
7.3.4.5;4.5 Further Work;41
7.3.5;5 Conclusion;41
7.3.6;References;41
8;Mechanics, Modeling and Simulation of Burr Formation;43
8.1;Burr and Cap Formation by Orbital Drilling of Aluminum;44
8.1.1;1 Introduction;44
8.1.2;2 Target of the Orbital Drilling Investigation;45
8.1.3;3 Orbital Drilling;45
8.1.3.1;3.1 Periphery and Front Cutting Zone;46
8.1.3.2;3.2 Machine Tool Data;46
8.1.4;4 Cap Formation on the Bore Exit Side;46
8.1.4.1;4.1 Cap Formation on the Bore Exit Side in Aluminum 2024 T351;47
8.1.4.2;4.2 Feed Rate Influence on the Cap Formation in Aluminum 2024 T351;48
8.1.4.3;4.3 Influence of Tool and Bore Diameter Ratio on the Cap Formation in Aluminum 2024 T351;48
8.1.5;5 Cap and Burr Formation in Primed Clad Aluminum 2024 T351;49
8.1.5.1;5.1 Primed Clad Aluminum;49
8.1.5.2;5.2 Tool Geometries;49
8.1.5.3;5.3 Forces in Orbital Drilling Primed Clad Aluminum 2024 T351;50
8.1.5.4;5.4 Geometries of the Orbital Drilling Caps and Burrs;52
8.1.6;6 Conclusion and Outlook;57
8.1.7;References;58
8.2;Cutting Force Model for Analysis of Burr Formation in Drilling Process;59
8.2.1;1 Introduction;59
8.2.2;2 Force Model in Drilling Process;60
8.2.2.1;2.1 Definition of Tool Geometry;60
8.2.2.2;2.2 Chip Formation in the Drilling Process;61
8.2.2.3;2.3 Analysis of Cutting Force;61
8.2.3;3 Force Analysis for Burr Formation;63
8.2.3.1;3.1 Case Study;63
8.2.3.2;3.2 Effect of Tool Geometry on Burr Formation;64
8.2.4;4 Conclusion;65
8.2.5;References;65
8.3;Burr Formation in Microstructuring Processes;66
8.3.1;1 Introduction;66
8.3.2;2 Burr Formation in Microstructuring Processes;66
8.3.2.1;2.1 Experimental Setup of the Fly-Cutting Process;67
8.3.2.2;2.2 Characterization of the Burr Formation;68
8.3.3;3 Influence of the Process Input Parameters on the Burr Formation;68
8.3.3.1;3.1 Influence of the Material and the Cutting Edge Radius on the Burr Formation;68
8.3.3.2;3.2 Influence of the Tool Cutting Edge Angle on the Burr Formation;70
8.3.4;4 Deburring Process;73
8.3.5;5 Summary;73
8.3.6;References;73
8.4;Analytical Modeling and Experimental Investigationof Burr Formation in Grinding;74
8.4.1;1 Introduction;74
8.4.2;2 Burr Formation in Grinding;74
8.4.3;3 Analytical Modeling of Burr Formation in Up-Cut Grinding;76
8.4.4;4 Experimental Investigation of Burr Formation in Up-Cut Grinding;77
8.4.4.1;5.1 Exit Burr Formation;78
8.4.4.2;5.2 Side Burr Formation;79
8.4.4.3;5.3 Thermal Impact on Side Burr Formation During a Grinding Pass;80
8.4.5;5 Conclusion and Outlook;82
8.4.6;References;82
8.5;Developing a Process Model for Abrasive Flow Machining;83
8.5.1;1 Introduction;83
8.5.2;2 Experimental Setup;83
8.5.3;3 Deburring Mechanism Using AFM;84
8.5.4;4 Developing a Numerical Model;85
8.5.4.1;4.1 Comparison of the Mean Cutting Velocity of Abrasive Grains;86
8.5.5;5 Approach for a Process Model;87
8.5.6;6 Conclusion and Outlook;87
8.5.7;References;88
8.6;Modeling and Simulation of Burr Formation: State-of-the-Artand Future Trends;89
8.6.1;1 Introduction;89
8.6.2;2 Predictive Models;90
8.6.2.1;2.1 ''Simplified'' Mechanical Models;90
8.6.2.2;2.2 Slip-Line Models;91
8.6.3;3 Numerical Methods;92
8.6.3.1;3.1 General Overview;92
8.6.3.2;3.2 Influence of Friction;93
8.6.3.3;3.3 New Continuum-Mechanical Parameters Applied to Burr-Formation;94
8.6.3.3.1;3.3.1 The Principle of the Hydrostatic Bowl;94
8.6.3.4;3.4 Material Influence on Burr Formation;94
8.6.3.5;3.5 Concept of Ductile Damage According to Lemaitre and Sievert;94
8.6.4;4 Conclusions and Outlook;95
8.6.5;References;95
9;Burr and Chip Formation Mechanisms;97
9.1;Interfacial Burr Formation in Drilling of Stacked Aerospace Materials;98
9.1.1;1 Introduction;98
9.1.2;2 Experimental Work;99
9.1.2.1;2.1 Drilling Parameter Experiments;99
9.1.2.2;2.2 Drill Wear Experiments;100
9.1.3;3 Measurements;101
9.1.3.1;3.1 Drilling Parameter Experiments;101
9.1.3.2;3.2 Drill Wear Experiments;101
9.1.4;4 Results;101
9.1.4.1;4.1 Drilling Parameter Experiments;102
9.1.4.2;4.2 Drill Wear Experiments;102
9.1.5;5 Conclusions;105
9.1.6;References;107
9.2;Burr Formation in Drilling Intersecting Holes;108
9.2.1;1 Introduction;108
9.2.2;2 State of the Art;108
9.2.3;3 Matter of Investigation;109
9.2.4;4 Process Model;109
9.2.5;5 Experimental Investigations;110
9.2.6;6 Relationship of Kinematical Process Model and Experimental Investigation;113
9.2.7;7 Summary;113
9.2.8;References;114
9.3;Chip Breakage Prediction by a Web-based Expert System;115
9.3.1;1 Introduction;115
9.3.2;2 Approach;115
9.3.2.1;2.1 Investigations of Chip Flow and Chip Breakage Mechanisms;115
9.3.2.2;2.2 Relevance and Weighting of Influences Regarding Chip Breakage;117
9.3.3;3 Database;117
9.3.4;4 Search for Similar Applications;118
9.3.5;5 Chip Breakage Prediction;119
9.3.6;6 Investigations on the Tool Influence;119
9.3.7;7 Implementation;120
9.3.8;8 Conclusion and Outlook;121
9.3.9;References;121
10;Parameters with Influence on Burr Formation;122
10.1;Size Effects in Drilling Burr Formation;123
10.1.1;1 Introduction;123
10.1.2;2 Drilling Test;124
10.1.2.1;2.1 Experimental Setup of Macroscopic Test;124
10.1.2.2;2.2 Micro Drilling Test Setup;125
10.1.2.3;2.3 Test Series;126
10.1.3;3 Results;126
10.1.3.1;3.1 Size Effects in Macroscopic Range;126
10.1.3.1.1;3.1.1 Burr Geometries;126
10.1.3.1.2;3.1.2 Burr Formation Mechanism and Cutting Forces for Different Burr Types;128
10.1.3.1.3;3.1.3 Thermal Distribution During Burr Formation;129
10.1.3.2;3.2 Micro Drilling Burrs in Comparison to Macroscopic Drilling Burrs;130
10.1.3.2.1;3.2.1 Burr Heights and Burr Types in Micro Drilling;130
10.1.3.2.2;3.2.2 Micro Burr Formation;131
10.1.4;4 Conclusion and Outlook;132
10.1.5;References;132
10.2;Burr Formation and Surface Characteristics in Micro-End Milling of Titanium Alloys;134
10.2.1;1 Introduction;108
10.2.2;2 Micro-Cutting and Burr Classification;108
10.2.2.1;2.1 Micro-Cutting;134
10.2.2.2;2.2 Burrs in Micro-Milling;135
10.2.3;3 Micro-End Mills;110
10.2.3.1;3.1 Micro-End Mill Properties;136
10.2.3.2;3.2 Manufacturing of Micro-End Mills;137
10.2.4;4 Titanium Alloys Ti-6Al-7Nb and Ti-6Al-4V;137
10.2.5;5 Experimental Set-Up;138
10.2.6;6 Results;138
10.2.6.1;6.1 Surface Characteristics of Large Area Machining;138
10.2.6.2;6.2 Burrs on Microslots;140
10.2.6.3;6.3 Up Milling and Down Milling Effects on Side Walls in Microslots;140
10.2.6.4;6.4 Up Milling and Down Milling of Side Walls;141
10.2.6.5;6.5 Chip Formation and Sidewall Generation;141
10.2.7;7 Conclusions and Outlook;141
10.2.8;References;114
10.3;Influence of Minimum Quantity Lubrication on Burr Formation in Milling;144
10.3.1;1 Introduction;144
10.3.2;2 Investigations into Burr Formation in Milling;144
10.3.3;3 Definition of Burr and Burr Parameters;145
10.3.3.1;3.1 Measuring Points in Angle and Face Milling;145
10.3.4;4 Test Procedure;146
10.3.5;5 Burr Formation in Angle Up-Milling;147
10.3.5.1;5.1 Influence of Minimum Quantity;147
10.3.5.2;5.2 Influence of Cutting Speed;148
10.3.5.3;5.3 Influence of Feed;148
10.3.5.4;5.4 Influence of Width of Cut;148
10.3.5.5;5.5 Influence of Corner Radius;149
10.3.5.6;5.6 Influence of Supply;149
10.3.6;6 Burr Formation in Angle Down-Milling;150
10.3.7;7 Burr Formation in Face Milling;150
10.3.8;8 Conclusion;151
10.3.9;References;151
10.4;Burr Formation and Removal at Profile Grinding of Riblet Structures;152
10.4.1;1 Introduction;152
10.4.2;2 Burr Formation at Riblet-Grinding;153
10.4.2.1;2.1 Experimental Setup;134
10.4.2.2;2.2 Characterization of the Burr Formation at Riblet-Grinding;154
10.4.3;3 Influence of the Grinding Process on the Burr Formation;155
10.4.3.1;3.1 Grinding Strategy;155
10.4.3.2;3.2 Grinding Wheel Specifications;156
10.4.3.3;3.3 Grinding Parameters;156
10.4.4;4 Burr Formation Mechanisms;157
10.4.5;5 Deburring Process;157
10.4.6;6 Summary;158
10.4.7;References;159
11;Burr Measurement;160
11.1;Burr Measurement System for Drilled Hole at Inclined Exit Surface;161
11.1.1;1 Introduction;161
11.1.2;2 Description of the System;161
11.1.2.1;2.1 Conoscopic Holography Sensor;162
11.1.2.2;2.2 Measurement System;163
11.1.2.3;2.3 Softwares;163
11.1.3;3 Analysis of Measurement Data;164
11.1.3.1;3.1 Error Elimination;165
11.1.3.2;3.2 Characterize Burr Geometry;165
11.1.4;4 Experiment Result;166
11.1.5;5 Conclusions;168
11.1.6;References;169
11.2;Burr Measurement: A Round Robin Test Comparing Different Methods;170
11.2.1;1 Introduction;170
11.2.2;2 Burr Values;170
11.2.3;3 Burr Measurement Systems;170
11.2.3.1;3.1 Optical Systems;171
11.2.3.2;3.2 Tactile Systems;172
11.2.3.3;3.3 Destructive Measurement;172
11.2.4;4 Round Robin;172
11.2.4.1;4.1 Design of Workpieces;173
11.2.4.2;4.2 Applied Measurement Methods;173
11.2.4.2.1;4.2.1 Digital Fringe Projection;173
11.2.4.2.2;4.2.2 Confocal Measurement System Depth of Focus (DoF);173
11.2.4.2.3;4.2.3 Confocal White Light Interferometer;175
11.2.4.2.4;4.2.4 Non-Contact 3D Measurement System;175
11.2.4.2.5;4.2.5 Stylus Profilometer;175
11.2.4.2.6;4.2.6 Metallographic Cross Sections;175
11.2.5;5 Results of the Round Robin;176
11.2.5.1;5.1 Burrs from Drilling Operations;176
11.2.5.2;5.2 Burrs from Milling Operations;178
11.2.6;6 Summary and Conclusions;178
11.2.7;References;181
12;Deburring Processes Fundamentals;182
12.1;Deburring with CO2 Snow Blasting;183
12.1.1;1 Introduction;183
12.1.2;2 Fundamentals of Blasting with Solid Carbon Dioxide;183
12.1.2.1;2.1 Properties of Carbon Dioxide;183
12.1.2.2;2.2 Working Mechanism;184
12.1.2.3;2.3 Process Variants;185
12.1.3;3 Motivation;186
12.1.4;4 Experimental Analyses;186
12.1.5;5 Results;187
12.1.6;6 Conclusion and Outlook;188
12.1.7;References;189
12.2;A Study on Deburring Inconel 718 Using Water Jet Technology;190
12.2.1;1 Introduction;190
12.2.2;2 Water Jet and Burrs;190
12.2.3;3 Experimental Set-Up;191
12.2.4;4 Experimental Procedure;192
12.2.5;5 Results and Discussion;192
12.2.6;6 Conclusion and Outlook;194
12.2.7;References;196
12.3;Ice Blasting 0 An Innovative Concept for the Problem-Oriented Deburring of Workpieces;197
12.3.1;1 Introduction;197
12.3.2;2 Theoretical Backgrounds;198
12.3.2.1;2.1 Ice as an Abrasive Blast Medium;198
12.3.2.2;2.2 Mechanism of Ice Blasting;198
12.3.3;3 Process Descriptions;199
12.3.3.1;3.1 The Production Process of Blast Ice;199
12.3.3.2;3.2 The Ice Blasting Process;200
12.3.4;4 Practical Investigations of the Removal Capacity of Deep Frozen Ice;200
12.3.5;5 Summary and Outlook;201
12.3.6;References;201
13;Deburring Processes Applications;202
13.1;Study of Internal Deburring of Capillary Tubes with Multiple Laser-machined Slits;203
13.1.1;1 Introduction;203
13.1.2;2 Processing Principle;204
13.1.3;3 Experimental Setup and Conditions;204
13.1.3.1;3.1 Experimental Setup;205
13.1.3.2;3.2 Finishing Conditions;205
13.1.4;4 Finishing Characteristics;206
13.1.5;5 Conclusions;210
13.1.6;References;201
13.2;Robotic Deburring Based on On-line Burr Measurement;211
13.2.1;1 Introduction;211
13.2.2;2 Robotic Deburring System;212
13.2.3;3 Modeling of Deburring Process;213
13.2.3.1;3.1 Burr Classification;213
13.2.3.2;3.2 Deburring Modeling;213
13.2.3.3;3.3 Deburring Simulation;215
13.2.4;4 Deburring Control Experiment;216
13.2.5;5 Concluding Remarks;218
13.2.6;References;218
13.3;Deburring Machine for Round Billets 0 Equipment for Efficient Removal of Burrs from Billets;219
13.3.1;1 Introduction;219
13.3.2;2 State of the Art;219
13.3.3;3 The New Approach;220
13.3.4;4 Constructional Implementation of the Deburring Machine;220
13.3.4.1;4.1 Basic Strategy;220
13.3.4.2;4.2 Basic Requirements to the Deburring Machine;220
13.3.4.3;4.3 Description of the Deburring Machine;221
13.3.5;5 Deburring Results with the Test Machine;222
13.3.6;6 Conclusion;223
14;Removal and Cleanability;225
14.1;Formulation of the Chip Cleanability Mechanics from Fluid Transport;226
14.1.1;1 Introduction;226
14.1.2;2 Experimental Setup;227
14.1.3;3 Formulation of Cleanability Mechanics: Observations and Inferences;227
14.1.3.1;3.1 Chip Critical and Workpiece Bottleneck Dimensions;228
14.1.3.2;3.2 Importance of Chip Projected Surface Areas: Role of Fluid Drag and Lift Forces;229
14.1.3.3;3.3 Chip Orientation Effects;231
14.1.3.4;3.4 Effect of Back Pressure on the Chip Transport;231
14.1.4;4 Chip Optimization Model;231
14.1.5;5 Conclusion;231
14.1.6;References;232
14.2;Burr Minimization and Removal by Micro Milling Strategies or Micro Peening Processes;233
14.2.1;1 Introduction;233
14.2.2;2 Material, Procedure and Experimental Set-up;233
14.2.2.1;2.1 Material;234
14.2.2.2;2.2 Micro Milling;234
14.2.2.3;2.3 Micro Peening;234
14.2.2.4;2.4 Ultrasonic Wet Peening;235
14.2.2.5;2.5 Surface Characterization Methods;235
14.2.3;3 Sample Preparation;235
14.2.3.1;3.1 Cavities;235
14.2.3.2;3.2 Burrs;236
14.2.4;4 Results of Deburring;236
14.2.4.1;4.1 Micro Milling;236
14.2.4.2;4.2 Abrasive Micro Peening;236
14.2.4.3;4.3 Ultrasonic Wet Peening;237
14.2.4.4;4.4 Discussion;238
14.2.5;5 Conclusion and Outlook;238
14.2.6;References;238
14.3;Assessment of Deburring Costs in Industrial Case Studies;240
14.3.1;1 Introduction;240
14.3.2;2 Case Study 1: Disc Brakes;240
14.3.3;3 Case Study 2: Steering Knuckles;241
14.3.4;4 Case Study 3: Flange for Oil Pipes;241
14.3.5;5 Case Study 4: Gear;241
14.3.6;6 Case Study 5: Flange;242
14.3.7;7 Case Study 6: Disc;242
14.3.8;8 Case Study 7: Compressor Casing;243
14.3.9;9 Conclusions;243
14.3.10;References;246
15;Author Index;247