Professional Documents
Culture Documents
on
Sangkee Min, Ph.D. Postdoctoral Researcher The Laboratory for Manufacturing Automation Professor David A. Dornfeld, Ph.D. The Department of Mechanical Engineering The University of California at Berkeley Berkeley, California 94720-1740, U.S.A. http://lma.berkeley.edu
for
Published by: AMT The Association for Manufacturing Technology 7901 Westpark Drive, McLean, VA 22102 Printed in the United States of America Copyright 2004 AMT The Association for Manufacturing Technology all rights reserved. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.
Index
Preface 1. Introduction 1.1. Definition of the burr 1.2. Burr geometry 1.3. Burr formation mechanism 1.4. Burr types 1 2 3 4 5 10
2. Burr metrology 2.1. Classification and standard 2.1.1. Classification of burrs in general machining x L. K. Gillespie x Yokohama National University, Japan 2.1.2. Classification of burrs in face milling 2.1.3. Classification of burrs in drilling 2.1.4. Survey of standards of burr and edge 2.2. Measurement system and sensor 2.2.1. Burr size measurement using a capacitance sensor 2.2.2. Burr size measurement using a laser displacement sensor 2.2.3. Measurement of drilling burr by image processing technique
13 13 13 13 14 16 18 20 21 21 22 23
3. Understanding of burr formation 3.1. Analytical modeling 3.1.1. Analytical modeling of burr formation in orthogonal cutting 3.1.2. Analytical modeling of edge breakout in orthogonal cutting 3.1.3. Analytical modeling of burr formation and fracture in oblique cutting 3.1.4. Analytical modeling of burr formation in milling 3.1.5. Analytical modeling of burr formation in drilling 3.1.6. Modeling of burr formation at various exit surface geometry in drilling 3.2. Empirical modeling 3.2.1. Exit failure in interrupted cutting 3.2.2. Effect of axial rake angle on burr formation in face milling 3.2.3. Effect of in-plane exit angle on burr formation and classification of burrs in face milling 3.2.4. Various burrs in square shoulder face milling 3.2.5. Burr formation in side-milling cutters 3.2.6. Burr formation in drilling small holes 3.2.7. Drilling burr formation in titanium alloy (Ti-6Al-4V) 3.2.8. Influence of workpiece exit angle on burr formation in drilling intersecting holes 3.2.9. Burr formation in drilling of intersecting hole with gun and twist drills 3.2.10. Statistical study of burr formation and hole quality in drilling
24 24 24 25 26 27 28 29 30 30 31
32 33 34 35 36 37 38 39
Relationships between hole quality and drilling forces Effect of process parameters on surface finish of drilled holes Entrance and exit burr formation in drilling and reaming Study on mechanism and similarity of burr formation in face milling and drilling 3.2.15. Formation and properties of burrs in various machining processes 3.3. Computer based modeling 3.3.1. Finite element modeling of burr formation in orthogonal cutting 3.3.2. Finite element analysis of the influences of exit angle and rake angle on burr formation in orthogonal cutting 3.3.3. Finite element modeling of burr formation in oblique cutting 3.3.4. Finite element analysis of mechanical state on sequentially machined surfaces 3.3.5. Finite element modeling of burr formation in drilling 3.3.6. Thrust force analysis of drilling burr formation using finite element method 3.4. Other approaches 3.4.1. Probabilistic prediction of burr formation of carbon steel (AISI 1045) in face milling 3.4.2. Prediction of burr size using neural networks and fuzzy logic in face milling 3.4.3. Drilling burr control charts for stainless steel (AISI 304L) and low alloy steel (AISI 4118)
40 41 42 43 44 45 45 47 48 50 51 53 54 54 55 56
4. Burr minimization and prevention 4.1. Process planning 4.1.1. Burr minimization in face milling by geometric approach 4.1.2. Multi-agent process planning for a networked machining service 4.1.3. Prediction and simulation of milling burr formation for edge-precision process planning 4.1.4. Geometric approaches for reducing burr formation in planar milling by avoiding tool exits 4.1.5. Tool path planning for exit burr minimization by estimating the total length of primary burrs 4.1.6. Avoiding tool exit in planar milling by adjusting width of cut 4.1.7. Burr minimization in face milling 4.1.8. Feature sequencing for burr minimization 4.1.9. Various methods to minimize the burr formation in milling and drilling 4.2. Tool development 4.2.1. Influence of approach angle on minimizing the burr size in metal cutting 4.2.2. Development of the drill attachment for drilling burr minimization 4.3. Alternative processes 4.3.1. Low frequency vibratory drilling for burr minimization 4.3.2. Burrless drilling by ultrasonic vibration
58 58 58 59 60 61 63 64 66 67 68
69 69 70 71 71 72
4.4. Expert systems 4.4.1. Architecture for integrated design and manufacturing for burr minimization of precision mechanical components 4.4.2. Burr expert systems for milling and drilling 4.5. Other approaches 4.5.1. Finite element analysis of burr minimization with a backup material in orthogonal cutting 4.5.2. Finite element analysis of burr minimization with a backup material in drilling 4.5.3. Product design strategy for burr prevention
73 73 74 75 75 76 77
5. Deburring 5.1. Mechanical deburring 5.1.1. Barrel tumbling x University of Nottingham x University of Stuttgart 5.1.2. Vibratory deburring 5.1.3. Recipro deburring 5.1.4. Flow finishing 5.1.5. Abrasive jet deburring x Indian Institute of Technology, Bombay x Lawrence Technological University 5.1.6. Automated deburring with a filamentary brush 5.1.7. Development of deburring machines for precision parts in mass production 5.1.8. Development of design rules for robot deburring 5.1.9. Intelligent deburring robot based on human demonstration 5.1.10. Ultrasonic deburring 5.2. Thermal deburring 5.2.1. Laser deburring x Hanyang University, Korea x University of California at Berkeley 5.2.2. Thermal energy deburring 5.3. Chemical deburring 5.3.1. Development of chemical solutions for ferrous alloys 5.3.2. Chemical accelerators 5.3.3. Thermochemical deburring 5.4. Electrical deburring 5.4.1. Electrochemical deburring 5.4.2. Rotolytic finishing 5.5. Other approaches 5.5.1. Burr prediction and cost function for deburring
78 80 80 80 81 82 83 84 85 85 86 87 88 89 90 91 92 92 92 93 94 95 95 96 97 98 98 99 100 100
Acoustic emission feedback for precision deburring Design of an efficient deburring tool path Strategies to minimize deburring costs Overview of deburring and edge finishing
6. Miscellaneous Area 6.1. Micro-burrs 6.1.1. Burr formation in micro-grooving of optical components 6.1.2. Burr formation in micro-machining of aluminum alloy (Al 6061-T6) 6.1.3. Burr formation in high speed micro-deep drilling 6.1.4. Removal of burr in micro-grooves 6.1.5. Measurement and effective deburring of micro-burrs in piercing operation 6.1.6. Molecular dynamics simulations of burr formation in nanometric cutting 6.2. Research technology 6.2.1. Integration of CAD model of the drill with FEA for drilling burr simulation 6.2.2. An analysis of the burrs in drilling precision miniature holes using Fractional Factorial Design References
105 105 105 106 107 108 109 110 112 112
113 114
Preface
This report was based on an extensive survey of printed literature and website information. We have used our best efforts to locate and access the most updated information on concurrent research projects worldwide in the area of burr formation, deburring and related finishing areas. We caution the reader that some contact information and/or the current status of some research projects may be outdated or incorrect. We also mention that a substantial portion of the information reviewed comes from our own work at Berkeley. In spite of the tremendous importance of this area, there are a limited number of research activities in this ongoing in the world. We have tried to include the widest possible base of information from all available sources in our review. There are a number of excellent general sources for some of this information identified in the body of the report. We have adopted a format for reporting on other specific projects used in other AMT Technology Assessment Reports. The authors would like to express their appreciation to the members and friends of the Consortium on Deburring and Edge Finishing (CODEF) at Berkeley whose information and financial support have made possible much of the information reported in this document. We acknowledge the helpful discussions over many years with our collaborators at Boeing (Paul Ffield), Daimler-Chrysler (Klaus Berger) and Ford Motor Company (Rich Furness and Tim Hull). In particular, the work of the following students is acknowledged as some information was drawn from their reports while students at Berkeley: Emanuel Chibesakunda, Ingo Essel, Christian Rosier, Boris Stirn, and Henning Storhaug. We also appreciate Shantanu Tripathi and Soyeon Kim for their great assistance. Finally, the authors appreciate the opportunity presented by AMT to prepare this work and we hope that it is useful.
1. Introduction
A burr is formed due to incompleteness of cutting mechanism during machining process in general. Machining is not necessarily only the process creating the burr but it is the most concerned process in the burr related industry and academia. All machining processes intend to process a raw or partially shaped workpiece material into a designed shape with a specific size and tolerance. A fundamental weakness in machining processes, that a cutting always requires a sustainable workpiece material, however, causes bending or break-off of the workpiece material. The result of the former is the burr and that of the latter is the edge break. Machining processes are most widely used in manufacturing industry. Therefore, the burr, an unintended outcome of machining processes, has been a widely recognized problem to the industry. It ruins the design integrity of the part, requires additional processes to fix it, causes safety hazards, and results in malfunction of the product. All these side effects represent unnecessary cost to the industry in various forms such as additional manufacturing, compensation, service, recall, and collateral damage on the company image. Therefore, in most cases, it is a must either to remove or to secure the burr in order to prevent it from being detached from the part. Traditionally, burr problems had been considered unavoidable so that most efforts had been made on removal of the burr as a post process. Naturally, many deburring processes have been developed and for their effectiveness and competitiveness, many research have been conducted. Nowadays, a trend of manufacturing is an integration of the whole production flow from design to final product. Manufacturing issues are handled in various stages even from design stage. Therefore, the methods of describing the burr are getting much attention in recent years for the systematic approach to resolve the burr problem at various manufacturing stages. Since the burr can be formed in many machining processes, its shape, size, and cause of formation have huge variety. Even for the same machining process, it can be totally differently viewed depending on the industry. Hence, definitions and described characteristics for the same burr are infinitely found. For the same reason, there is no internationally recognized definition or standard on the burr and its related terminologies. Fortunately, there has been an activity to create an international standard on the burr. And also, many research groups have proposed ways to define and classify the burr. Some of these efforts are summarized in chapter 2.
burr-free
sharp-edged
burr overhang
One of the latest definitions regarding burrs was introduced by Gillespie in a draft for the World-wide Burr Technology Committee (WBTC) [4] which is a consortia of the following national associations: Burr, Edge and Surface Technology of China (BEST-C) Burr, Edge and Surface Technology of Japan (BEST-J) Burr, Edge and Surface Technology of Korea (BEST-K) Burr, Edge and Surface Technology of Russia (BEST-R) Burr, Edge and Surface Technology of USA (BEST-USA) Contrary to the German understanding of burrs, Gillespies definition of the burr is limited to cutting and shearing processes. A burr produced through those operations includes all the material extending past the theoretical intersection of two surfaces, which surround the burr. Because the reference in that case is the theoretical intersection of the two surfaces and not the desired surface, Gillespie states that burrs could also lie inside the theoretical intersection as shown in Figure 1.2.
burr
burr
hf
bg
The longitudinal profile of the burr is not very informative, and is rarely used to describe burrs. The length of the burr is of some interest only because it describes how much of the total edge length that has burrs, and this is directly related to the deburring time of the work piece. In other words it gives an estimate on how long time and then how much it will cost to deburr the part. Still it is most common to refer to parameters of the burr cross sectional profile when describing burrs. Link [5] proposed a measure called Gratwert using the quantities defined by Schfer. The Gratwert g gives a comparable sense of the deburring effort, which is defined as:
4 b f 2 rf bg h 8
Contrary to the description of the burr geometry above, the DIN-standard uses only one value to define the deviation from the ideal geometrical outline of the edge, Figure 1.4. The size of the edge area is termed edge measure a. This value is measured from the burr tip perpendicular to the work piece surface from which the burr is protruding.
The prior-mentioned burr-formation stages were indicated by deformation mechanisms. As soon as crack initiates, it is useful to distinguish between the further development of burr formation by ductile (d) and brittle (b) materials, respectively. Starting from the tool tip in the primary shear zone, the crack initiation (d-6) follows the cutting line. This is explainable due to the materials properties. Ductile materials have a large critical fracture strain, and the strain in the negative shear zone is smaller than the critical strain of the material. Thus, the crack initiates in the direction of the lowest resistance. During the crack-growth (d-7) stage, the tool makes the crack grow as well as deforms the workpiece so that the resulting crack growth seems to appear along the cutting line. The last stage is characterized by the positive burr (d-8), which remains on the workpiece corner. This marks the end of burr formation. Contrary to ductile materials, brittle materials have a small critical fracture strain, therefore, the direction of the pivoting point exhibits the smallest resistance. The crack initiation (b-6) propagates this way. The crack growth (b-7) takes place along the negative shear zone. The end of burr formation is built up by a negative burr (b-8) that remains on the workpiece edge as a result of a separation from the chip and that part of the workpiece that is above the negative shear line.
Continuous Cutting
Pre-Initiation
Initiation
Pivoting
Burr Development
1 1
2 2
3 3
4 4
5 5
Ductile Materials
Crack Initiation
Crack Growth
Positive Burr
6 6
7 7
8 8
Brittle Materials
Crack Initiation
Crack Growth
6 6
7 7
8 8
Min et. al. [7] proposed a burr formation model for a uniform burr and a crown burr which can be found in most of alloy steel, stainless steel, and some aluminum alloys. Their model is based on experimental observations using high speed camera and FEM simulations. Burr formation mechanism is divided into five stages: (a) steady-state, (b) initiation, (c) development, (d) initial fracture, and (e) final burr formation for both burr types in Table 1.1 and Table 1.2. The thrust force induced by many cutting parameters causes different initiation points and initial fracture locations, which leads to different burr types. During the steady-state cutting stage, material in front of the drill tip is removed as elements comprising that portion meet the failure criterion and a plastic zone appears near the center of the drill tip. As the drill advances, the plastic zone near the center of the drill tip reaches the exit surface of the workpiece at the burr initiation stage. As soon as the plastic zone reaches near the center of the hole on the exit surface, plastic deformation is initiated. Up to this point, material is mainly cut by the cutting edge of the drill. After the burr initiation point, bending mechanism slowly takes over cutting mechanism. For a uniform burr, this plastic zone appears at the exit surface of the workpiece when the drill almost reaches the exit surface. Hence, the layer between the exit surface and the drill tip is thin. By contrast, the plastic zone reaches the exit surface when the drill is far away from that surface and forms a thick plastic layer for a crown burr. The thickness of the layer at the burr initiation point defines burr formation behavior in the following stages: development and initial fracture. The thin layer of the plastic zone in the uniform burr does not have enough support to be cut by the drill and so rapid transition from cutting to bending occurs. Thus, very little cutting at the perimeter of the drill occurs during the development stage, Table 1.1 (c). The plastic zone that initially formed near the center of the drill area expands to the edge of the drill and plastic deformation spreads out. The thick layer of the plastic zone in the crown burr has more stiffness than that in the uniform burr. Hence, transition from cutting to bending is very slow, which enables more material to be cut during the development stage and allows very little expanding of the plastic zone to the edge of the drill, Table 1.2 (c). In the uniform burr, the material in front of the chisel edge of the drill undergoes mainly plastic deformation without cutting during the development stage and at certain point, is just pushed away by the chisel edge because the rotational cutting speed at the center of the drill is zero and the thin layer of the material cannot sustain cutting force. However, the material near the edge of the drill connected to the large material area that has enough stiffness to support cutting force still undergoes cutting and bending with high rotational cutting speed. Therefore, material near the edge of the drill becomes thinner and initial fracture occurs at the edge of the drill, Table 1.1 (d) and it leads to the formation of cap, Table 1.1 (e). However, in the crown burr, a larger thrust force induces plastic deformation earlier in the process. The thicker material layer in front of the chisel edge of the drill still undergoes plastic deformation and cannot be simply pushed away because it is connected to stiffer area that can support thrust force. A larger maximum strain is induced near center of the exit surface. When this maximum strain exceeds the fracture strain of the workpiece material, initial fracture occurs at the center of the drill, Table 1.2 (d) and the rest of material deforms plastically and forms a crown burr, Table 1.2 (e). The five stages of the uniform burr and the crown burr are compared with the proposed mechanism [8] and high-speed camera images (top view) [9] in Table 1.1 and Table 1.2.
Table 1.1 Burr formation mechanism of a uniform burr in AISI 304L [7] Proposed burr formation mechanism [8]
FEM simulation
(a) Steady-state
(b) Initiation
(c) Development
Table 1.2 Burr formation mechanism of a crown burr in AISI 304L [7]
FEM simulation
(a) Steady-state
(b) Initiation
(c) Development
Rollover burr: The rollover burr is basically a chip which is pushed out of the cutters path rather than being sheared. Typically, it is a long burr formed at the end of the cut. The formation of rollover burrs predominates in most cutting operations involving ductile materials, Figure 1.7.
Tear burr: The tear burr is the result of material tearing loose from the work piece rather than being sheared, Figure 1.8.
Cut-off burr: The cut-off burr is the result of a separation from the raw material before the separation cut is finished. Whenever a part is allowed to fall back down before the cut is completed, a cut-off burr remains on the part. This burr type often occurs on saw cuts. Similar to this classification, another commonly used method to define and classify the burr is to look at its shape and formation mechanism. The reason why the shape plays an important role is that in most cases, it is closely related to the burr formation mechanism and in turn, proper selection of deburring technology and development of burr prevention/minimization strategy. Burrs representing combinations of the above mentioned types are most likely to be observed. But one mode of formation usually dominates Figure 1.9 shows some typical burrs found in drilling metals.
Reference:
[1] Schfer, F., Gratbildung und Entgraten beim Umfangsstirnfrsen, VDI-Z 120, Nr. 1 / 2, 1978. [2] Ko, S. L., Dornfeld, D. A., A study on burr formation mechanisms, ASME Transactions, Journal of Engineering Materials and Technology, vol. 113, no. 1, pp. 75-87, 1991. [3] N. N., Werkstckkanten, Deutsches Institut fr Normung (DIN), Beuth Verlag Kln Berlin, DIN 6784, 1982. [4] Gillespie, L. K., Standard Terminology for Researchers of Burrs and Edge Finishing, World-wide Burr Technology Committee WBTC STD-02, 1996. [5] Link, R., Gratbildung und Strategien zur Gratreduzierung, Ph. D. Dissertation, RheinischWestsfaelische Technische Hochschule (RWTH) Aachen, 1992. [6] Hashimura, M., Chang, Y. P., Dornfeld, D. A., Analysis of Burr Formation Mechanism in Orthgonal Cutting, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 1-7, 1999. [7] Min, S., Dornfeld, D. A., Kim, J., Shyu, B., Finite Element Modeling of Burr Formation in Metal Cutting, International Journal of Machining Science and Technology, vol. 5, no. 3, pp. 307-322, 2001. [8] Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001. [9] Furness, R. J., Video Tape of Exit Burr Formation of Carbon Steel, Ford Motor Company, 1998. [10] Gillespie, L. K., Blotter, P. T., (1976), Formation and Properties of Machining Burrs, ASME Transactions, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74.
2. Burr metrology
2.1. Classification and standard 2.1.1. Classification of burrs in general machining
CATEGORY: Burr metrology SUB-CATEGORY: Classification and standard CONTACT INFORMATION: LaRoux K. Gillespie Deburring Technology International 1300 East 109th Street Kansas City, MO 64131-3585, USA laroux@kctera.net ABSTRACT This research group proposed a burr classification scheme based on its formation mechanism regardless of machining process. A Poisson burr is formed by lateral flow of material, a roll-over burr by bending of material such as chip roll-over, a tear burr by tearing of chip from the workpiece (or when the punch tears the part from the stock in stamping process), a recast burr by redeposition of material, cutoff burr by incomplete cutoff of material, and finally a flash burr by flow of material into cracks. Basic characteristics of each type of burr were established and their empirical models were proposed. Also, burrs produced by many manufacturing processes were classified. KEY ISSUES FOR THIS PROGRAM Classification of burrs based on formation mechanism in general machining STATUS: On going REFERENCE: [1] Gillespie, L. K., Burrs Produced by Drilling, Bendix Corporation Unclassified Topical Report, BDX-613-1248, 1975. [2] Gillespie, L. K., The Formation and Properties of Burrs, SME Technical Report, MRR75-03, 1975. [3] Gillespie, L. K., Blotter, P. T., Formation and Properties of Machining Burrs, Transactions of the ASME, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74, 1976.
B (Backward or entrance burr) S (Sideward burr) F (Forward or exit burr) L (Leaned burr)
KEY ISSUES FOR THIS PROGRAM Classification of face milling burr Burr minimization in face milling STATUS: Closed REFERENCE: Nakayama K., Arai, M., Burr Formation in Metal Cutting, Annals of the CIRP, vol. 36, no. 1, pp. 3336, 1987.
Tool
ABSTRACT This research group proposed a classification of milling burrs based on burr location, shape and mechanism. Several methods and classification schemes were proposed by this group. The milling burrs were classified according to three locations, five shapes and four burr formation mechanisms based on fractography.
Chip
Figure 2.2 Cutting edges Table 2.2 Burr classification [1] Location Surface Machined surface Surface cut by minor edge Transition surface Surface cut by major edge Top surface Surface cut by major edge Top burr Name Exit burr Remains attaching to machined surface Shape (Macro view) Discontinuous Type Mechanism (Micro view) Ductile plus fracture (DF) Facture plus ductile (FD) Fracture (F) Completely ductile (CD)
Continuous Discontinuous (DC) Spiral (S) Continuous (C) Discontinuous Ragged Longitudinal
Side burr
The results in burr research were effective on the specific cases but it is difficult to apply to other conditions, because burrs found in production lines were various in shape and size. Therefore generalized and systematic understanding of formation mechanism for various burrs was required. Moreover the classification based on formation mechanism is considered to be useful to solve the burr problems in future. From the basic classification as described in the above table, this group has kept improving their classification and adding more feature onto it. One of the classifications is shown in Figure 2.3.
KEY ISSUES FOR THIS PROGRAM Burr classification depending on burr location, shape, and formation mechanism in face milling STATUS: On going REFERENCE: [11] Hashimura, M., Hassamontr, J., Dornfeld, D.A., Effect of In-Plane Exit Angle and Rake Angles on Burr Height and Thickness in Face Milling Operation, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 13-19, 1999. [12] Hashimura, M., Ueda, K., Dornfeld, D.A., Manabe, K., Analysis of Three Dimensional Burr Formation in Oblique Cutting, CIRP Annals, vol. 44, no.1, pp. 27-30, 1995. [13] Hashimura, M., Dornfeld, D. A., Proposal of a Burr Classification Method Based on the Formation Mechanisms in Face Milling, Journal of the Japan Society of Precision Engineering, vol. 65, no. 6, pp. 872-877, 1999. [14] Hashimura, M., Dornfeld, D. A., Proposal of a Burr Classification Method Based on the Formation Mechanisms in Face Milling (2nd Report), Journal of the Japan Society of Precision Engineering, vol. 65, no. 7, pp. 1002-1007, 1999. [15] Meum, E., System for Burr Measurement, Diploma thesis, Norwegian University of Science and Technology, 2001.
KEY ISSUES FOR THIS PROGRAM Classification of burrs in drilling of stainless steel (AISI 304L) and low alloy steel (AISI 4118) STATUS: On going REFERENCE: [1] Kim, J., Dornfeld, D. A., Furness, R., Experimental Study of Burr Formation in Drilling of Intersecting Holes with Gun Drill and Twist Drills, Technical Papers of NAMRI/ SME, pp. 39-44, 1999.
[2] Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Stainless Steel, Transactions of NAMRI/ SME, vol. 28, pp. 317-322, 2000. [3] Min, S., Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Low Alloy Steel, AISI 4118, Journal of Materials Processing Technology, vol. 113, no. 1-3, pp. 4-9, 2001. [4] Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001.
KEY ISSUES FOR THIS PROGRAM Burr standards STATUS: Closed REFERENCE: Ohmori, K., Investigations and Studies for Standards of Edge, Iwata Denko Company, Technical Report.
2.2. Measurement system and sensor 2.2.1. Burr size measurement using a capacitance sensor
CATEGORY: Burr metrology SUB-CATEGORY: Measurement system and sensor CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group used a capacitance sensor to develop an on-line burr measurement system. A non-contact capacitance gauging sensor was attached to an ultra precision milling machine which was used as a positioning system. The setup was used to measure burr profiles along the machined workpiece edges. Experimental procedures and results as well as the basic theoretical principles of the capacitance sensor and specifications of related equipment were proposed. The proposed scheme was accurate, easy to setup, and with minor modifications, readily applicable to automatic deburring processes. KEY ISSUES FOR THIS PROGRAM Burr size measurement STATUS: Closed REFERENCE: Lee, S. H., Park, D. S., Dornfeld, D. A., Burr Size Measurement using a Capacitance Sensor, Proceedings of Second S. M. Wu Symposium on Manufacturing Science, SME, pp. 31-36, 1996.
ABSTRACT This research group used a laser displacement sensor (LDS) to measure the burr height in order to assist efficient robot deburring. A LDS can project a laser beam with no more than 230 Pm in beam diameter onto a reflective object surface. The sensor can estimate the travel distance of the laser beam between the target object and a receptor on the sensor with an accuracy as high as 0.5 Pm when measuring a white flat surface. Applications of this sensor are primarily for short distance on displacement measurement, such as sheet metal thickness, small gap width on printed circuit boards, or fluttering of rotating disks. The sensor was mounted on the deburring robot and the burr height was measured as the distance between the edge of the burr and the desired workpiece surface location. In order to evaluate the performance of this measuring system, the burr size was compared with other measurement results. The results showed good agreement with other measurements. KEY ISSUES FOR THIS PROGRAM Burr size measurement STATUS: Closed REFERENCE: Shimokura, K., Liu, S., Programming Deburring Robots Based on Human Demonstration with Direct Burr Size Measurement, Proceedings of IEEE International Conference on Robotics and Automation, pp. 572-577, 1994.
3.2.3. Effect of in-plane exit angle on burr formation and classification of burrs in face milling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu G. Barrow Department of Mechanical Engineering University of Manchester Institute of Science and Technology P.O. Box 88, Sackville St. Manchester, M60 1QD, U.K. http://www.me.umist.ac.uk/staffpgs/GB.htm ABSTRACT This research group investigated three-dimensional characteristics of burr formation in face milling with respect to in-plane exit angle using stainless steel (AISI 304L). An important aspect of the three-dimensional effects is the exit order of the tool edges because the burr remains near the final exit position of the tool along the workpiece edge. The geometric parameters of the workpiece and tools were varied to change exit order in the workpiece around the cutting edge. The exit burr on the exit surface and the side burr on transition surface of workpiece were analyzed. The effect of in-plane exit angle and radial rake angle on burr formation were shown and the burr formation mechanism for each burr was also discussed. KEY ISSUES FOR THIS PROGRAM Concept of exit order and in-plane exit angle and their influence on burr formation in face milling STATUS: On going REFERENCE: [1] Hashimura, M., Hassamontr, J., Dornfeld, D.A., Effect of In-Plane Exit Angle and Rake Angles on Burr Height and Thickness in Face Milling Operation, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 13-19, 1999. [2] Hashimura, M., Ueda, K., Manabe, K., Dornfeld, D. A., Effect of In-plane Exit and Radial Rake Angle on Burr Formation in Face Milling, Journal of the Japan Society of Precision Engineering, vol. 66, no. 1, pp. 85-90, 2000. [3] Olvera, O., Barrow, G., Influence of exit angle and tool nose geometry on burr formation in face milling operations, Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture, vol. 212, no. 1, pp. 59-72, 1998.
KEY ISSUES FOR THIS PROGRAM Understanding burr formation by side-milling cutters STATUS: Closed REFERENCE: Gillespie, L. K., Burrs Produced by Side-Milling Cutters, Bendix Corporation Unclassified Topical Report, BDX-613-1303, 1975.
3.2.8. Influence of workpiece exit angle on burr formation in drilling intersecting holes
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Intersecting drilled holes frequently occur in many production situations. In a drilling operation, inclination or curvature of the exit surface causes a variation of the workpiece exit angle around the periphery of the hole, unlike the constant exit angle value of 90 degrees observed in planar exit surface drilling. A fractional factorial experimental design was used to investigate the importance of drilling process parameters, drill point geometry and drilling workpiece exit angles in the modeling of the drilling burr formation process for 0,036 (0.91mm) intersecting holes in 304L stainless steel. The workpiece exit angle in drilling is an important factor in determining burr size and shape. The shape of the burrs around on-axis holes was more uniform than the shape for off-axis holes, and this difference was probably determined by the variation in exit angles between the two configurations. The burrs in on-axis hole drilling are more desirable in shape than those in off-axis hole drilling, but they may be less predictable in size. The burrs in off-axis hole drilling occur in a fairly predictable pattern and the burr sizes for in both on-axis and off-axis intersecting hole drilling. KEY ISSUES FOR THIS PROGRAM Burr formation in intersecting holes STATUS: On going REFERENCE: Stein J. M., Dornfeld D. A., Influence of Workpiece Exit Angle on Burr Formation in Drilling Intersecting Holes, Transactions of NAMRI/ SME, vol. 24, pp. 39-44, 1996.
3.2.9. Burr formation in drilling of intersecting hole with gun and twist drills
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group investigated the mechanism of the burr formation in drilling of intersecting holes with a gun drill and two types of twist drills. Three different inclination angles, feed rates and cutting speeds were selected to determine their influences on burr formation. The burr formation mechanism of a gun drill as well as a twist drill was proposed and a qualitative comparison of burr shapes created by different drill types was performed. The maximum burr height in each condition was measured. It was found that geometric parameters played the most dominant role in determining burr size. KEY ISSUES FOR THIS PROGRAM Burr formation in intersecting holes using gun and twist drills STATUS: Closed REFERENCE: Kim, J., Dornfeld, D. A., Furness, R. J., Experimental Study of Burr Formation in Drilling of Intersecting Holes with Gun Drill and Twist Drills, Technical Papers of NAMRI/ SME, pp. 39-44, 1999.
3.2.14. Study on mechanism and similarity of burr formation in face milling and drilling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Empirical modeling CONTACT INFORMATION: Koya Takazawa Kanagawa Institute of Technology Kamakura, Kanagawa, Japan bestjap@juno.ocn.ne.jp ABSTRACT This research group conducted comparative study on burrs produced in face milling and drilling. The workpiece used in the experiment was carbon steel for machine structural use (S45C in JIS, 179HB). The mechanism of burr formation in face milling was similar to that in drilling. Namely, in both cutting operations the sudden decrease of burr height, which is caused by the separation of the tip of the burr (secondary burr formation), occurred and the influence of depth of cut and feed rate on burr formation was also similar. KEY ISSUES FOR THIS PROGRAM Comparative study on burr formation in face milling and drilling STATUS: Closed REFERENCE: [1] Kitajima, K., Miyake, T., Yamamoto, A., Tanaka, Y., Takazawa, K., Study on Mechanism and Similarity of Burr Formation in Face Milling and Drilling, Technology Reports of Kansai University, no. 32, 1990. [2] Miyake, T., Yamamoto, A., Kitajima, K., Tanaka, Y., Takazawa, K., Study on Mechanism of Burr Formation in Drilling. Deformation of Material during Burr Formation, Journal of the Japan Society of Precision Engineering, vol. 57, no. 3, pp. 485-490, 1991.
3.3. Computer based modeling 3.3.1. Finite element modeling of burr formation in orthogonal cutting
CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group studied burr formation mechanism in orthogonal cutting using a finite element method (FEM). The study proposed a basic framework for and conceptual understanding of the burr formation process based upon the material properties of the workpiece. In order to verify this framework and explain the basic phenomena in the burr formation process, the deformation at the edge of the workpiece was analyzed using a finite element method. Burr formation mechanisms for ductile and brittle materials were proposed from FEM analysis and experimental observations. Micro-machining tests under an optical microscope and a scanning electron microscope using Al 2024-O and copper were also conducted to observe the burr formation process. The feed rate and tool edge radius were varied and the resulting burr formation observed. FEM analysis of burr formation in this material and observation of the deformation at the workpiece edge in the micromachining test verified the proposed conceptual understanding of the burr formation process. For the experimental conditions examined, all of the burrs in Al 2024-O were negative burrs, that is, edge breakout. As the feed was increased, two effects were observed. One effect was an increase in the resulting burr thickness. Another effect, which was observed during the burr initiation stage while machining with a sharp tool, was an increase in both the distance and depth of the initial pivoting point of the burr from the tool edge.
(a) Steady-state
(d) Pivoting
(e) Final
(f) Burr
(g) Steady-state
(h) Initiation
(i) Pivoting
(j) Final
(k) Burr
Figure 3.2 Schematic illustration of the burr formation process [1] KEY ISSUES FOR THIS PROGRAM FE modeling of burr formation in orthogonal cutting Burr formation mechanisms for ductile and brittle materials Micro-machining of aluminum alloy (Al 2040-O) and copper for validation experiment STATUS: Closed REFERENCE: [1] Hashimura, M., Chang, Y. P., Dornfeld, D. A., Analysis of Burr Formation Mechanism in Orthgonal Cutting, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 1-7, 1999. [2] Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part I, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 221-228, 2000.
3.3.2. Finite element analysis of the influences of exit angle and rake angle on burr formation in orthogonal cutting
CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group investigated the influences of exit angles of the workpiece and tool rake angles on burr formation processes in 304L stainless steel using finite element models in orthogonal cutting. Based on the metal cutting FE simulation procedure, a series of stress and strain contours and final burr/breakout configurations were obtained. The burr formation mechanisms with respect to five different exit angles were found, and duration of the burr formation process increased with an increase of exit angle, resulting in different burr/breakout configurations. Based on the development of negative shear stress in front of the tool tip, the tool tip damage, what is called chipping, was investigated. Also, with fixed cutting conditions and workpiece exit geometry, the influence of the rake angle was found to be closely related to the rate of plastic work in steady-state cutting because the larger the rate of plastic work in steady-state cutting, the earlier the burr initiation commences. KEY ISSUES FOR THIS PROGRAM Parametric study of burr formation with respect to exit angle of the workpiece and rake angle of the tool using FE model Relationship between burr/breakout and cutting parameters STATUS: Closed REFERENCE: Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part II - The Influences of Exit Angle, Rake Angle, and Backup Material on Burr Formation Processes, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 229-237, 2000.
Figure 3.3 Burr formation mechanisms for orthogonal and oblique cutting [1] KEY ISSUES FOR THIS PROGRAM FE modeling of burr formation in oblique cutting Relationship between inclination angle and burr formation/edge breakout STATUS: Closed
REFERENCE: [1] Hashimura, M., Ueda, K., Dornfeld, D.A., Manabe, K., Analysis of Three Dimensional Burr Formation in Oblique Cutting, CIRP Annals, vol. 44, no.1, pp. 27-30, 1995. [2] Ko, S. L., Donrfeld, D. A., Burr Formation and Fracture in Oblique Cutting, Journal of Materials Processing Technology, vol. 62, no. 1-3, pp. 24-36, 1996.
Uniform burr
Steady-state cutting
Crown burr
Steady-state cutting
Burr initiation Plastic deformation at the center (thin) Development Plastic zone expands with little cutting Initial fracture Fracture at the edge of the drill Burr formation Burr and cap formation
Burr initiation Plastic deformation at the center (thick) Development Plastic zone expands with little cutting Initial fracture Fracture at the center of the drill Burr formation Burr and cap formation
KEY ISSUES FOR THIS PROGRAM Material modeling under high strain dynamics Efficient modeling technique to reduce computation time Empirical evaluation of new tool design for burr minimization STATUS: On going REFERENCE: [1] Min, S., Dornfeld, D. A., Kim, J., Shyu, B., Finite Element Modeling of Burr Formation in Metal Cutting, International Journal of Machining Science and Technology, vol. 5, no. 3, pp. 307-322, 2001. [2] Choi, J., Min, S., Dornfeld, D. A., Alam, M., Tzong, T., Modeling of Inter-layer Gap Formation in Drilling of a Multi-layered Material, 6th CIRP International Workshop on Modeling of Machining Operations, Hamilton, Ontario, Canada, May, 2003. [3] Min, S., Modeling of Drilling Burr Formation and Development of Expert System, Ph.D. Dissertation, Department of Mechanical Engineering, University of California, CA, USA, 2001. [4] Guo, Y. B., Dornfeld, D. A., Finite Element Modeling of Drilling Burr Formation Process in Drilling 304 Stainless Steel, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 122, no. 4, pp. 612-619, 2000.
3.3.6. Thrust force analysis of drilling burr formation using finite element method
CATEGORY: Understanding of burr formation SUB-CATEGORY: Computer based modeling CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group conducted thrust force analysis of the drilling burr formation. A finite element model for drilling burr formation was used. A stainless steel workpiece (AISI 304L) and a conventional twist drill were used for both simulation and experiments. The thrust force variation during drilling process from FEM was obtained and compared with the experimental results. The estimation of burr size is briefly discussed. A constant thrust force was observed during steady-state cutting. As feed increases, thrust force in steady-state cutting increases and so does burr size. The burr initiation point was defined where an abrupt fluctuation in thrust force occurred when the exit surface reached its yield point, which was observed in both simulation and experiments. The burr initiation point is important because it results in different burr types. KEY ISSUES FOR THIS PROGRAM Burr initiation point and thrust force relationship in drilling STATUS: On going REFERENCE: Min, S., Kim, J., Dornfeld, D. A., Thrust Force Analysis of Drilling Burr Formation Using Finite Element Method, Proceedings of the 10th International Conference Precision Engineering, Yokohama, Japan, pp. 169-173, 2001.
3.4. Other approaches 3.4.1. Probabilistic prediction of burr formation of carbon steel (AISI 1045) in face milling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group used Bayesian probabilistic model to supplement and update existing experimental database on face milling burrs. Face milling burrs of ductile materials such as a carbon steel (AISI 1045) exhibited three distinct burr types, uniform, wavy, and secondary burrs. It was found that the three burr types are dependent on the in-plane exit angle, undeformed chip ratio, and undeformed chip area at the exit stage of cut. The empirical equations, representing the burr transition curves from the relationship, a probabilistic model, in which the operational Bayesian modeling approach was adopted to include the empirical equations, was derived. The probabilistic model is capable of predicting burr types under given cutting conditions and updating its probability density as new data becomes available.
KEY ISSUES FOR THIS PROGRAM Probabilistic burr prediction model for AISI 1045 carbon steel in face milling STATUS: On going REFERENCE: Ahn, S., Park, I. W., Dornfeld, D. A., Probabilistic Prediction of Burr Patterns of 1045 Carbon Steel in Face Milling, Machining Science and Technology, vol. 6, no. 2, pp. 151-170, 2002.
3.4.2. Prediction of burr size using neural networks and fuzzy logic in face milling
CATEGORY: Understanding of burr formation SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This study aimed to build a procedure for estimating and predicting burr size in face milling. Application of neural network and fuzzy logic techniques for burr formation modeling were analyzed to assist in the selection of optimal cutting parameters minimizing burr formation. Both neural networks and fuzzy logic were successfully applied to model burr formation in face milling. The established set of criteria allowed the comparison of both techniques according to their accuracy in model building. The simulations conducted revealed that with relatively small structures of neural nets or fuzzy logic it was possible to represent such a complicated phenomenon as the primary and secondary burr formation. Comparing the results of simulations from a model accuracy point of view, it was noted that neural networks serve as a universal technique to model burr formation, not only for one workpiece material but for the whole set of materials as well. Also, the generalization ability of both techniques allowed the reduction of the data set necessary to build a relationship between exit angle, cutting parameters and burr height. A relatively small set of data makes both modeling techniques very attractive from the practical application point of view. KEY ISSUES FOR THIS PROGRAM Burr prediction using neural networks and fuzzy logic in face milling STATUS: On going REFERENCE: Sokolowski, A., Narayanaswami, R., Dornfeld, D. A., Prediction of Burr Size using Neural Networks and Fuzzy Logic, Proceedings of Japan-USA Symposium on Flexible Automation, ISCIE, Kobe, Japan, pp. 889-896, 1994.
3.4.3. Drilling burr control charts for stainless steel (AISI 304L) and low alloy steel (AISI 4118)
CATEGORY: Understanding of burr formation SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a control chart to understand burr formation with respect to cutting parameters. It can be used for finding optimal process parameters in consideration of burr minimization and productivity. The concept can be expanded to other related parameters such as tool geometry and workpiece material property. The chart, based on experimental data, is a tool for prediction and control of drilling burrs. Control charts for drilling burr formation for stainless (AISI 304L) and low alloy steel (AISI 4118) with a split point twist drill were developed. Burr classification was carried out based on the geometric characteristics, burr formation mechanisms, and sizes of the burrs. Two types of burrs, uniform burr (type I: small uniform burr, type II: large uniform burr) and crown burr, for stainless steel and three types of burrs, uniform burr (type I: small uniform burr, type II: large uniform burr), transient burr, and crown burr, for low alloy steel were found. New parameters consisting of process parameters and drill diameter were developed, and used to show a unique distribution of the burr types. Burr types and the resultant burr size showed great dependence on the new parameters regardless of the drill diameter. Through the chart, burr type can be predicted as a function of given cutting conditions. Also cutting conditions that are believed to create preferred burr types can be selected.
Transient burr
(b) Drilling burr control chart for AISI 4118 Figure 3.4 Drilling Burr Control Chart [3] ( Fn is a non-dimensionalized feed parameter and S is a cutting speed parameter) KEY ISSUES FOR THIS PROGRAM Drilling burr control chart for burr prediction and process planning STATUS: On going REFERENCE: [1] Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Stainless Steel, Transactions of NAMRI/ SME, vol. 28, pp. 317-322, 2000. [2] Min, S., Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Low Alloy Steel, AISI 4118, Journal of Materials Processing Technology, vol. 113, no. 1-3, pp. 4-9, 2001. [3] Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001.
4.1.3. Prediction and simulation of milling burr formation for edge-precision process planning
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a burr prediction and simulation system for edge-precision process planning in planar milling. Given workpiece geometry, cutting parameters, and tool path, this system first classifies the workpiece edges according to different burr formation mechanisms obtained experimental studies. For each edge type, tool engagement conditions is computed for inquiry generation to corresponding database, in which burr type is predicted with different criteria. The location of each type of burr is graphically displayed along the workpiece edges. This project provided and based a systematic approach for the use of experimental data on milling burr formation represented in different form. Burr prediction was integrated into the process planning stage, providing effective tools that help reduce milling burr formation and deburring cost. KEY ISSUES FOR THIS PROGRAM Edge recognition from CAD file of the workpiece Burr prediction by tool engagement on workpiece edges STATUS: On going REFERENCE: Chu, C. H., Dornfeld, D. A., Brennum, C., Prediction and Simulation of Milling Burr Formation for Edge-Precision Process Planning, Proceedings of the 3rd International Conference on Integrated Design and Manufacturing in Mechanical Engineering, Montreal, Canada, 2000.
4.1.4. Geometric approaches for reducing burr formation in planar milling by avoiding tool exits
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group found that one of the most effective methods for reducing milling burr formation is to prevent the tool from exiting the workpiece. Exit here refers specifically to the tool cutting edges moving out of the workpiece at an edge while removing material. Under this circumstance only entrance burrs can occur, which is usually extremely small and negligible. This group designed a set of geometric algorithms for avoiding tool exits in planar milling. Two distinct approaches were developed for tool path planning of 2D polygons. The first approach generates exit-free tool paths by offsetting the workpiece edges with appropriate widths of cut. The second one locally adjusts tool positions on given tool paths. In addition, a two-stage algorithm was designed for 2D free form contours. The cutter locations that cause the tool to exit the workpiece are first detected. Then a heuristic scheme is applied to generate new cutter locations with no tool exits. Experimental results showed that edge quality were significantly improved using the proposed methods. This work provided a feasible way to minimize burr formation in an automatic manner, reducing deburring process.
KEY ISSUES FOR THIS PROGRAM Burr prevention algorithm by avoiding tool exit STATUS: On going REFERENCE: [1] Chu, C. H., Dornfeld, D. A., Tool Path Planning for Avoiding Exit Burrs, Journal of Manufacturing Processes, vol. 2, no. 2, pp.116-123, 2000. [2] Hassamontr J., Blondaz, L., Dornfeld, D. A., Avoiding Exit Burr in CNC End Milling By an Adapted Tool Path, ASME IMECE, Anaheim, CA, USA, pp. 497-501, 1998.
4.1.5. Tool path planning for exit burr minimization by estimating the total length of primary burrs
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Experimental studies show that the in-plane exit angle is a crucial factor affecting the burr formation in the face milling operation. Primary burrs are likely to form when the exit angle is larger than a threshold value, which is determined by other cutting parameters such as depth of cut and feed rate. This research group developed an algorithm for estimating the total length of primary burrs in face milling of 2D parts. Compared to previous work, this algorithm was more efficient and also applicable to multiple tool paths as well as work parts with curved edges and inner profiles. A tool path planning system was developed using this algorithm. Exit burr minimization was achieved by selecting tool feed directions and simulation of primary burr location. KEY ISSUES FOR THIS PROGRAM Burr prevention algorithm by estimating the length of primary burrs STATUS: On going REFERENCE: Chu, C. H., Dornfeld, D. A., Tool Path Planning for Exit Burr Minimization by Estimating the Total Length of Primary Burrs, International Journal of Computer Integrated Manufacturing Systems, Submitted for publication, 2003.
Figure 4.3 Avoiding tool exit when a straight edge intersects a second circular edge [1] (a) The sense of the circular edge is clockwise (b) The sense of the circular edge is counter clockwise
Figure 4.4 Avoiding tool exit when a circular edge intersects a second straight edge [1] (c) The sense of the circular edge is clockwise (d) The sense of the circular edge is counter clockwise
KEY ISSUES FOR THIS PROGRAM Burr prevention algorithm by adjusting width of cut (offset method) Longer tool path problem STATUS: On going REFERENCE: [1] Rangarajan, A., Chu, C. H., Dornfeld, D. A., Avoiding Tool Exit in Planar Milling by Adjusting Width of Cut, Proceeding of the ASME, Manufacturing in Engineering Division, MED-vol. 11, pp. 1017-1025, 2000.
4.1.9. Various methods to minimize the burr formation in milling and drilling
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Process planning CONTACT INFORMATION: Wang Guicheng Jiangsu University of Science and Technology Zhenjiang, China 212013 ABSTRACT This research group proposed several ways to minimize the burr formation in drilling and milling. Main influence factors on burrs were investigated; they were support rigidity at the end of workpiece and cutting force and its direction in metal cutting. And furthermore, use of backup material, adjustment of cutting parameters, chamfer at the end of the workpiece, selection of form of the cutting tool and other methods to control and decrease burr formation in drilling and milling process were suggested. KEY ISSUES FOR THIS PROGRAM Burr minimization through process parameters and tool design STATUS: On going REFERENCE: Guicheng, W., Controlling Ways of the Burrs in Metal Cutting, the 1st Asia Pacific and 2nd JapanChina International Conference on Progress of Cutting and Grinding, pp. 641-646, 1994.
4.2. Tool development 4.2.1. Influence of approach angle on minimizing the burr size in metal cutting
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Tool development CONTACT INFORMATION: Rikio Hikiji Department of Mechanical Engineering Kagoshima National College of Technology 1460-1 Shinko, Hayato-cho, Aira-gun Kagoshima 899-51, JAPAN hikiji@kagoshima-ct.ac.jp http://www.kagoshima-ct.ac.jp/dps/mech/hikiji/hikiji.html ABSTRACT This research group proposed burr minimization by optimal value of the approach angle in metal cutting. The approach angle of the cutting tool influenced remarkably the burr size. The effects of the approach angle on the burr root thickness were investigated experimentally, and as a result, the new geometry of the cutting tool edge was proposed for burr minimization. The following results were obtained: (1) when the approach angle was 80 or more, the burr root thickness decreased remarkably with the approach angle increasing in general metal cutting, (2) the finishing edge with the large approach angle decreased the burr root thickness remarkably, (3) the angle and length of finishing edges made as small as possible were more useful for controlling the generation of burr, and (4) the drill with finishing edges was efficient in making the burr root thickness as small as possible. KEY ISSUES FOR THIS PROGRAM Tool design using approach angle concept on burr minimization STATUS: On going REFERENCE: Hikiji, R., Arai, M., Kondo, E., Kawagoishi, N., A Study on Control for the Diminution of the Size of Burr in Metal Cutting, International Journal of Japan Society of Precision Engineering, vol. 31, no. 4, pp. 293-298, 1997.
4.3. Alternative processes 4.3.1. Low frequency vibratory drilling for burr minimization
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Alternative processes CONTACT INFORMATION: Professor Katsushige Adachi Osaka Industrial University 3-1-1, Nakagaito, Daito Osaka 674, Japan ABSTRACT This research group investigated the low frequency vibratory drilling method to minimize the burr formation. Effects of the cutting conditions and cutting force on burr shape during this drilling were examined and compared with those during the conventional drilling. It was found that the application of this method for drilling of aluminum would be effective to reduce burr formation. In case of carbon steel, the effect of this method was minimal. Using this method, the burr size was not influenced by the number of holes drilled while the burr size increased with conventional drilling. KEY ISSUES FOR THIS PROGRAM Low frequency vibratory drilling for burr minimization STATUS: On going REFERENCE: [1] Adachi, K., Arai, N., Okita, K., Wakisaka, S., Kuratani, F., Study on Burr in Low Frequency Vibratory Drilling Proceedings of the 5th International Conference on Production Engineering. Tokyo, Japan, pp.246-151, 1984. [2] Adachi, K., Arai, N., Harada, S., Okita, K., Wakisaka, S., A Study on Burr in Low Frequency Vibratory Drilling Drilling of Aluminum, Bulletin of the Japan Society of Precision Engineering, vol. 21, no. 4, pp. 258-264, 1987.
4.4. Expert systems 4.4.1. Architecture for integrated design and manufacturing for burr minimization of precision mechanical components
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Expert Systems CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Four levels of integration observed in the design to fabrication cycle of precision mechanical components were proposed. Burr formation was described as a process metric to illustrate the interactions between design and manufacturing decisions on the shape and size of the burrs formed. The types of interactions observed were utilized for a discussion about the levels of integration between design and manufacturing, and for the development of integrated design software. The architecture for the core burr software was developed and the lowest level of integration was tested through the enhancement of the core software for sensor-based robotic deburring process planning. KEY ISSUES FOR THIS PROGRAM Burr minimization strategy from design to manufacturing Basic architecture of burr expert system STATUS: On going REFERENCE: Stein, J. M., Dornfeld, D. A., An Architecture for Integrated Design and Manufacturing of Precision Mechanical Components, Transactions of NAMRI/SME, vol. 25, pp 249-254, 1997.
4.5. Other approaches 4.5.1. Finite element analysis of burr minimization with a backup material in orthogonal cutting
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT In order to effectively minimize the burr size in orthogonal cutting, three cases of backup material, thick backup, thin backup, and partial backup, were examined. A backup material, whose material properties are twice as stiff (Youngs modulus) and twice as strong (yielding and ultimate strength) as those of the workpiece material, was used. It was found that the burr size can be effectively minimized when the backup material supports the workpiece only up to the predefined machined surface. The backup material should be thick enough to allow only local deformation without bending of the backup. KEY ISSUES FOR THIS PROGRAM Burr minimization with backup material in orthogonal cutting STATUS: Closed REFERENCE: Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part II - The Influences of Exit Angle, Rake Angle, and Backup Material on Burr Formation Processes, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 229-237, 2000.
4.5.2. Finite element analysis of burr minimization with a backup material in drilling
CATEGORY: Burr minimization and prevention SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Using three-dimensional FE drilling models, this research group investigated two types of backup methods to minimize drilling burr formation and predict cutting forces. They accounted for temperature-mechanical coupling, automatic mesh contact with friction and material ductile failure simultaneously. Negative shear and gap formation between the part and the backup were dominant mechanisms of drilling burr formation. The use of a bushing backup having a zero clearance resulted in significantly shorter and thinner exit burrs than typical of conventional drilling methods. The use of a solid backup material was less effective in minimizing burr size superior to an unsupported exit surface. KEY ISSUES FOR THIS PROGRAM Burr minimization with backup material (solid and bushing backup) in drilling STATUS: Closed REFERENCE: Guo, Y. B. and Dornfeld, D. A., Finite Element Analysis of Drilling Burr Minimization with a Backup Material, Transactions of NAMRI/SME, vol. 26, pp. 207-212, 1998.
5. Deburring
Deburring includes all operations which are used to remove produced burr from simple hand deburring to high tech surface finishing by NC controlled robots. As a result of years of research, vast numbers of methods have been developed. Some typical deburring methods are introduced here with some research efforts. For better description of many deburring processes, LaRoux K. Gillespies Deburring and Edge Finishing Handbook published by SME in 1999 is recommended. According to his book, those deburring operations can be classified as follows. Mechanical deburring operations x Cutting based: Sanding Mechanical Cutting Vibratory conveyor Manual deburring Power brushing Mechanized cutting Wheel blending Edge rolling Trimming x Mass finishing: Barrel tumbling Cryogenic barrel tumbling Vibratory deburring Cryogenic vibratory finishing Roll flow finishing Spindle finishing Fluidized bed spindle finishing Centrifugal barrel finishing Recipro finishing Flow finishing Orboresonant finishing Magnetic loose abrasive x Other: Liquid abrasive flow Semi-solid abrasive flow Abrasive jet Cryogenic abrasive jet Water jet Lapping Ultrasonic slurry Thermal deburring operations Torch or flame melting Thermal energy method Plasma flame Plasma-glow deflashing Hot wire Resistance heating Laser deburring Electronic discharge machining (EDM)
Chemical deburring operations Chemical barrel finishing Chemical vibratory finishing Chemical roll flow finishing Chemical spindle finishing Chemical centrifugal finishing Chemical magnetic finishing Ultrasonic (chemical) Chemical fluidized bed Chlorine gas deburring Electrical deburring operations Electrochemical barrel tumbling Electrochemical vibratory finishing Electrochemical roll flow finishing Electrochemical spindle finishing Electrochemical recipro finishing Electrochemical orboresonant finishing Electrochemical moving electrode Electrochemical mesh deburring Electrochemical brush deburring Electrochemical deburring Electropolish deburring
5.3. Chemical deburring 5.3.1. Development of chemical solutions for ferrous alloys
CATEGORY: Deburring SUB-CATEGORY: Chemical deburring CONTACT INFORMATION: Huixin Jiang Institute of Material Research/Engineering of Singapore Singapore 117602, Singapore ABSTRACT This group tested oxalic acid for chemical polishing solution for ferrous alloys. Using this solution, a significant improvement on polishing and deburring of carbon steel surface was accomplished due to a relatively mild but effective polishing mechanism sustained by oxalic acid. Moreover, the bathlife of such polishing solution was prolonged because the decomposition of hydrogen peroxide was effectively restrained. Skipping the use of nitric acid also avoids the release of harmful nitrogen dioxide to the environment. KEY ISSUES FOR THIS PROGRAM Development of chemical deburring solutions for ferrous alloys STATUS: On going REFERENCE: Jiang, H., Chen, X., Hong, L., Mineral-acid-free Chemical Polishing Solutions for Ferrous Alloys, Applied Surface Science, vol. 218, no. 1-4, pp. 305-309, 2003.
5.5. Other approaches 5.5.1. Burr prediction and cost function for deburring
CATEGORY: Deburring SUB-CATEGORY: Other approaches CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT This research group developed a deburring cost function to evaluate the deburring complexity of part designs and to assist in process planning for burr minimization. The main factors influencing deburring complexity are identified to be burr location, length of edges to be deburred, number of edges to be deburred and burr size. A destructive solid geometry (DSG) approach was used to investigate the potential for burr formation on edges of the part. Difficult to deburr features were defined in terms of an attributed adjacency graph (AAG). The effect of the choice and sequence of machining volumes on the number of edges on which burrs are formed was also demonstrated. KEY ISSUES FOR THIS PROGRAM Deburring cost function depending on burr location, length and number of edges to be deburred STATUS: Closed REFERENCE: Narayanaswami, R., Dornfeld, D. A., Design and Process Planning Strategies for Burr Minimization and Deburring, Transactions of NAMRI/SME, vol. 28, pp.227-232, 2000, vol. 22, pp. 313-322, 1994.
6. Miscellaneous area
6.1. Micro-burrs 6.1.1. Burr formation in micro-grooving of optical components
CATEGORY: Miscellaneous area SUB-CATEGORY: Micro-burrs CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT Micro-groove, ranging in size from a few microns to several tens of microns, is the basic geometric shape of miniaturized/thinned optical components such as fresnel lens, lenticular lens, reflector, etc. Requirements of high precision shape/surface quality for optical parts to function as designed need such as ultra-precision machining with a single point diamond tool. It has also a unique advantage that various grooves can be made only by changing the tool geometry or the machining program. However, actual problems such as shape distortion and burr, which might be caused by high specific cutting force and ductile mold materials, is so undesirable because it absolutely degrade the performance of optical components. Many researches have been conducted about burr generation mechanism mostly in conventional machining. This research group investigated burr in a single groove, which swells up at both sides of a grove. A simplified model of the burr/shape distortion in grooving multiple micro-grooves was proposed and the effects of cutting parameters such as depth of cut, groove angle, etc. were experimentally investigated. It was found that the thrust force in micro-grooving plays a significant role in burr generation and shape distortion. Also, burr of micro-groove grew largely due to bending deformation caused by large groove angle and large depth of cut. A critical depth of cut, where an accumulated burr height was less than the projection of the accumulated depth of cut, was recommended for deburring after grooving. KEY ISSUES FOR THIS PROGRAM Burr formation in micro-grooving STATUS: Closed REFERENCE: Ahn, J. H., Lim, H. S., Dornfeld, D. A., Burr and Shape Distortion in Micro-Grooving of Optical Components, Proceedings of ASPE, vol. 14, pp. 496-499, 1996.
Figure 6.1 SEM of a structure cut into stainless steel. Burr occurs at the upper groove edges. The lower groove edges are rounded because of the wear of the tool tip. [1] KEY ISSUES FOR THIS PROGRAM Development of deburring technology for micro-grooves in stainless steel and brass STATUS: Closed REFERENCE: [1] Schaller, Th., Bohn, L., Mayer, J., Schubert, K., Microstructure Grooves with a Width of Less than 50 Pm Cut with Ground Hard Metal Micro End Mills, Precision Engineering, vol. 23, no. 4, pp. 229-235, 1999.
(b) ductile work material Figure 6.2 MD plots of two stages of the exit failure in nanometric cutting with no elastic constraint at the exit [1] KEY ISSUES FOR THIS PROGRAM Burr formation in nano-cutting STATUS: Closed REFERENCE: [1] Komanduri, R., Chandrasekaran, N., Raff, L. M., MD Simulation of Exit Failure in Nanometric Cutting, Materials Science and Engineering A, vol. 311, no. 1-2, pp. 1-12, 2001.
6.2. Research Technology 6.2.1. Integration of CAD model of the drill with FEA for drilling burr simulation
CATEGORY: Miscellaneous area SUB-CATEGORY: Research technology CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT The goal of this work was to develop an integrated CAD/FEA system for drill design and drilling burr formation process. A drill CAD module was developed and integrated with the FEA model of drilling burr formation process through the CAD interface. The proposed prototype of integration system allow for rapid use of the FE model for drilling burr analysis and extract the geometrical data from the drill CAD module automatically. Modification of drill design is fast and simple. The developed prototype system demonstrates the feasibility of imbedding the drill CAD system with the FEA program. KEY ISSUES FOR THIS PROGRAM Modeling and design of various drill types and testing their performance CAD/FEA integration STATUS: On going REFERENCE: Guo, Y., Dornfeld, D.A., Integration of CAD of Drill with FEA of Drilling Burr Formation, Transactions of NAMRI/SME, vol. 26, pp. 201-206, 1998.
6.2.2. An analysis of the burrs in drilling precision miniature holes using Fractional Factorial Design
CATEGORY: Miscellaneous area SUB-CATEGORY: Research technology CONTACT INFORMATION: Professor David A. Dornfeld Department of Mechanical Engineering 5100A Etcheverry Hall University of California Berkeley, CA 94720 dornfeld@me.berkeley.edu http://lma.berkeley.edu ABSTRACT A two level replicated fractional factorial design is used to investigate the effects of five factors on the exit burr thickness and height in the drilling of holes of diameter less than one millimeter in 304L stainless steel. The factors investigated are feed per revolution, cutting speed, drill pecking, drill wear and drill material. Increasing feed and cutting speed were found to increase the burr height and thickness, and the effect of increasing the feed was more pronounced at high cutting speeds. The effect of increase cutting speed effect is related to the increased cutting temperature observed in drilling holes with relatively high length to diameter ratios. Worn drills are shown to increase burr size and the variation in burr size for constant cutting conditions. Drill pecking is determined to be a stabilizing factor which increases the robustness of the burr formation process to changes in feed and cutting speed. KEY ISSUES FOR THIS PROGRAM Burr analysis using fractional factorial design STATUS: On going REFERENCE: Stein, J. M., Dornfeld, D. A., Analysis of the Burs in Drilling Precision Miniature Holes, Proceedings of the 1995 ASME International Mechanical Engineering Congress and Exposition, San Francisco, CA, USA, vol. 2-1, pp. 127-148, 1995.
References
Adachi, K., Arai, N., Okita, K., Wakisaka, S., Kuratani, F., Study on Burr in Low Frequency Vibratory Drilling Proceedings of the 5th International Conference on Production Engineering. Tokyo, Japan, pp.246-151, 1984. Adachi, K., Arai, N., Harada, S., Okita, K., Wakisaka, S., A Study on Burr in Low Frequency Vibratory Drilling Drilling of Aluminum, Bulletin of the Japan Society of Precision Engineering, vol. 21, no. 4, pp. 258-264, 1987. Ahn, J. H., Lim, H. S., Dornfeld, D. A., Burr and Shape Distortion in Micro-Grooving of Optical Components, Proceedings of ASPE, vol. 14, pp. 496-499, 1996. Ahn, S., Park, I. W., Dornfeld, D. A., Probabilistic Prediction of Burr Patterns of 1045 Carbon Steel in Face Milling, Machining Science and Technology, vol. 6, no. 2, pp. 151-170, 2002. Alwerfalli, D. R., Taraman, K. S., Chadda, Y. S., Burr Removal Rate Model for an Abrasive Jet Deburring Process, SME Technical Paper, MR89-441, 1989. Balasubramaniam, R., Krishnan, J., Ramakrishnan, N., Investigation of AJM for deburring, Journal of Materials Processing Technology,.vol. 79, no. 1-3, pp. 52-58, 1998. Balasubramaniam, R., Krishnan, J., Ramakrishnan, N., A study on the shape of the surface generated by abrasive jet machining, Journal of Materials Processing Technology,.vol. 121, no. 1, pp. 102-106, 2002. Blondaz, L., Brissaud, D., Dornfeld, D. A., Avoiding the Need for Deburring by Analyzing Burr Formation During Product Design, Proceedings of the 2nd International Conference on Integrated Design and Manufacturing in Mechanical Engineering, Compigne, France, 1998. Cariapa, V., Stango, R. J., Liang, S. K., Prasad, A., Measurement and Analysis of Brushing Tool Performance Characteristics, Part 2. Contact Zone Geometry, ASME Transactions, Journal of Engineering for Industry, vol. 113, no. 3, pp. 290-296, 1991. Chern, G., Donrfeld, D. A., Burr/Breakout Model Development and Experimental Verification, ASME Transactions, Journal of Engineering Materials and Technology, vol. 118, no. 2, pp. 201-206, 1996. Choi, J., Min, S., Dornfeld, D. A., Alam, M., Tzong, T., Modeling of Inter-layer Gap Formation in Drilling of a Multi-layered Material, 6th CIRP International Workshop on Modeling of Machining Operations, Hamilton, Ontario, Canada, May, 2003. Chu, C. H., Dornfeld, D. A., Brennum, C., Prediction and Simulation of Milling Burr Formation for Edge-Precision Process Planning, Proceedings of the 3rd International Conference on Integrated Design and Manufacturing in Mechanical Engineering, Montreal, Canada, 2000. Chu, C. H., Dornfeld, D. A., Tool Path Planning for Avoiding Exit Burrs, Journal of Manufacturing Processes, vol. 2, no. 2, pp.116-123, 2000. Chu, C. H., Dornfeld, D. A., Tool Path Planning for Exit Burr Minimization by Estimating the Total Length of Primary Burrs, International Journal of Computer Integrated Manufacturing Systems, Submitted for publication, 2003.
Dornfeld, D. A., Lisiewicz, Acoustic Emission Feedback for Precision Deburring, CIRP Annals, vol. 41, no. 1,pp. 93-96, 1992. Dornfeld, D. A., Wright, P. K., Process Planning for Agent-based Precision Manufacturing, Transactions of NAMRI/SME, vol. 25, pp. 359-364, 1997. Dornfeld, D. A., Wright, P. K., Wang, F., Sheng, P., Stori, J., Sundararajan, V., Krishnana, N., Chu, C., Multi-Agent Process Planning for a Networked Machining Service, Transactions of NAMRI/SME, vol. 27, pp. 191-196, 1999. Dornfeld, D. A., Kim, J., Dechow, H., Hewson, J., Chen, L. J., Drilling Burr Formation in Titanium Alloy, Ti-6Al-4V, CIRP Annals, vol. 48, no. 1, pp. 73-76, 1999. Furness, R. J., Lander, W. R., An Experimental Study of Exit Burr Formation and Hole Quality for Twist Drilling, Ford Motor Company Technical Report, SR-95-069, 1995. Furness, R. J., Video Tape of Exit Burr Formation of Carbon Steel, Ford Motor Company, 1998. Gillespie, L. K., The Formation and Properties of Burrs, SME Technical Report, MRR75-03, 1975. Gillespie, L. K., Quantitative Approach to Vibratory Deburring Effectiveness, SME Technical Paper, MRR75-11, 1975. Gillespie, L. K., Burrs Produced by Drilling, Bendix Corporation Unclassified Topical Report, BDX613-1248, 1975. Gillespie, L. K., Burrs Produced by Side-Milling Cutters, Bendix Corporation Unclassified Topical Report, BDX-613-1303, 1975. Gillespie, L. K., Hand Deburring of Precision Parts, Bendix Corporation Unclassified Topical Report, BDX-613-1443, 1975. Gillespie, L. K., Effects of Drilling Variables on Burr Properties, Bendix Corporation, Unclassified Topical Report, BDX-613-1502, 1976. Gillespie, L. K., Blotter, P. T., Formation and Properties of Machining Burrs, ASME Transactions, Journal of Engineering for Industry, vol. 98, no. 1, pp. 66-74, 1976. Gillespie, L. K., Deburring Precision Miniature Parts, Journal of the ASPE, Precision Engineering, vol. 1, no. 4, pp. 189-198, 1979. Gillespie, L. K., Standard Terminology for Researchers of Burrs and Edge Finishing, World-wide Burr Technology Committee WBTC STD-02, 1996. Gillespie, L. K., Deburring and Edge Finishing Handbook, SME, Dearborn, MI, USA, 1999. Guicheng, W., Controlling Ways of the Burrs in Metal Cutting, the 1st Asia Pacific and 2nd JapanChina International Conference on Progress of Cutting and Grinding, pp. 641-646, 1994. Guo, Y., Dornfeld, D.A., Integration of CAD of Drill with FEA of Drilling Burr Formation, Transactions of NAMRI/SME, vol. 26, pp. 201-206, 1998.
Guo, Y. B. and Dornfeld, D. A., Finite Element Analysis of Drilling Burr Minimization with a Backup Material, Transactions of NAMRI/SME, vol. 26, pp. 207-212, 1998. Guo, Y. B., Dornfeld, D. A., Finite Element Modeling of Drilling Burr Formation Process in Drilling 304 Stainless Steel, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 122, no. 4, pp. 612-619, 2000. Guo, Y. B., Liu, C. R., FEM Analysis of Mechanical State on Sequentially Machined Surfaces, Machining Science and Technology, vol. 6, no. 1, pp. 21-41, 2002. Hakim, M. A. E., Mahdy, M. A. M., Sayed, M. A., ECD Tooling Design, International Journal of Materials & Product Technology, vol. 13, no. 3-6, pp. 167-183, 1998. Hashimura, M., Ueda, K., Dornfeld, D.A., Manabe, K., Analysis of Three Dimensional Burr Formation in Oblique Cutting, CIRP Annals, vol. 44, no.1, pp. 27-30, 1995. Hashimura, M., Dornfeld, D. A., Effect of Axial Rake Angle on Burr Formation in Face Milling, Journal of Japan Society of Precision Engineering, vol. 64, no. 11, pp. 1658-1663, 1998. Hashimura, M., Hassamontr, J., Dornfeld, D.A., Effect of In-Plane Exit Angle and Rake Angles on Burr Height and Thickness in Face Milling Operation, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 13-19, 1999. Hashimura, M., Chang, Y. P., Dornfeld, D. A., Analysis of Burr Formation Mechanism in Orthgonal Cutting, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 1, pp. 1-7, 1999. Hashimura, M., Dornfeld, D. A., Proposal of a Burr Classification Method Based on the Formation Mechanisms in Face Milling, Journal of the Japan Society of Precision Engineering, vol. 65, no. 6, pp. 872-877, 1999. Hashimura, M., Dornfeld, D. A., Proposal of a Burr Classification Method Based on the Formation Mechanisms in Face Milling (2nd Report), Journal of the Japan Society of Precision Engineering, vol. 65, no. 7, pp. 1002-1007, 1999. Hashimura, M., Ueda, K., Manabe, K., Dornfeld, D. A., Effect of In-plane Exit and Radial Rake Angle on Burr Formation in Face Milling, Journal of the Japan Society of Precision Engineering, vol. 66, no. 1, pp. 85-90, 2000. Hassamontr J., Blondaz, L., Dornfeld, D. A., Avoiding Exit Burr in CNC End Milling By an Adapted Tool Path, ASME IMECE, Anaheim, CA, USA, pp. 497-501, 1998. Hassamontr, J., Dornfeld, D. A., On Designing and Efficient Deburring Tool Path, Proceedings of Symposium on Decision making in Design and Manufacturing, ASME IMECE, Nashville, TN, USA, 1999. Hassamontr, J., Dornfeld, D. A., Strategies to Minimize Deburring Costs, Proceedings of ASME Design Engineering Technical Conference (DETC99), Las Vegas, NV, USA, DETC99- DFM8927, 1999.
Hikiji, R., Arai, M., Kondo, E., Kawagoishi, N., A Study on Control for the Diminution of the Size of Burr in Metal Cutting, International Journal of Japan Society of Precision Engineering, vol. 31, no. 4, pp. 293-298, 1997. Iwata K., Moriwaki, T., Hoshi, T., Basic Study of High Speed Micro Deep Drilling, CIRP Annals, vol. 30, no. 1, pp. 27-30, 1981. Jiang, H., Chen, X., Hong, L., Mineral-acid-free Chemical Polishing Solutions for Ferrous Alloys, Applied Surface Science, vol. 218, no. 1-4, pp. 305-309, 2003. Kanda, Y. Shimda, H., Micro Deburring System for Engineering Plastics(1, 2), Proceedings of the 4th International Conference on Precision Surface Finishing and Burr Technology, Badenauheimn, Germany, 1996. Kim, J., Dornfeld, D. A., Furness, R. J., Experimental Study of Burr Formation in Drilling of Intersecting Holes with Gun Drill and Twist Drills, Technical Papers of NAMRI/SME, pp. 39-44, 1999. Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Stainless Steel, Transactions of NAMRI/SME, vol. 28, pp. 317-322, 2000. Kim, J., Min, S., Dornfeld, D. A., Optimization and Control of Drilling Burr Formation of AISI 304L and AISI 4118 based on Drilling Burr Control Charts, International Journal of Machine Tools & Manufacture, vol. 41, no. 7, pp. 923-936, 2001. Kitajima, K., Miyake, T., Yamamoto, A., Tanaka, Y., Takazawa, K., Study on Mechanism and Similarity of Burr Formation in Face Milling and Drilling, Technology Reports of Kansai University, no. 32, 1990. Ko, S. L., Dornfeld, D. A., A study on burr formation mechanisms, ASME Transactions, Journal of Engineering Materials and Technology, vol. 113, no. 1, pp. 75-87, 1991. Ko, S. L., Donrfeld, D. A., Burr Formation and Fracture in Oblique Cutting, Journal of Materials Processing Technology, vol. 62, no. 1-3, pp. 24-36, 1996. Ko, S. L., "Measurement and Effective Deburring for the Micro Burrs in Piercing Operation", International Journal of the Korean Society of Precision Engineering, vol.1, no.1, pp.152-159, 2000. Kobayashi, H., Kobayashi, F. Jr., Matsunaga, M., Deburring and Finishing by Recipro-finishing and Gyro-finishing Machines, SME Technical Paper, MR77-464, 1977. Komanduri, R., Chandrasekaran, N., Raff, L. M., MD Simulation of Exit Failure in Nanometric Cutting, Materials Science and Engineering A, vol. 311, no. 1-2, pp. 1-12, 2001. Kurobe, T., Yamada, Y., Sugimori, H., High Speed Slurry Flow Finishing of the Inner Wall of a Stainless Steel Pipe, Mechanical & Corrosion Properties, Series a (Key Engineering Materials), vol. 238-239, pp. 345-348, 2003. Lee, K., Stirn, B., Dornfeld, D. A., Burr Formation in Micro-machining Aluminum, 6061-T6, Proceedings of the 10th International Conference Precision Engineering, Yokohama, Japan, pp. 4751, 2001.
Lee, S. H., Park, D. S., Dornfeld, D. A., Burr Size Measurement using a Capacitance Sensor, Proceedings of Second S. M. Wu Symposium on Manufacturing Science, SME, pp. 31-36, 1996. Lee, S. H., Dornfeld, D. A., Precision Laser Deburring and Acoustic Emission Feedback, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 123, no. 2, pp. 356-364, 2001. Lee, S. H., Dornfeld, D. A., Precision Laser Deburring, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 123, no. 4, pp. 601-608, 2001. Link, R., Gratbildung und Strategien zur Gratreduzierung, Ph. D. Dissertation, RheinischWestsfaelische Technische Hochschule (RWTH) Aachen, 1992. Mauch, C. A., Saunders, L. Ken L., Modeling the drilling process. An analytical model to predict thrust force and torque, Winter Annual Meeting of the American Society of Mechanical Engineers Materials Division, vol. 20., pp. 59-65, 1990. Meum, E., System for Burr Measurement, Diploma thesis, Norwegian University of Science and Technology, 2001. Min, S., Dornfeld, D. A., Kim, J., Shyu, B., Finite Element Modeling of Burr Formation in Metal Cutting, International Journal of Machining Science and Technology, vol. 5, no. 3, pp. 307-322, 2001. Min, S., Kim, J., Dornfeld, D. A., Development of a Drilling Burr Control Chart for Low Alloy Steel, AISI 4118, Journal of Materials Processing Technology, vol. 113, no. 1-3, pp. 4-9, 2001. Min, S., Kim, J., Dornfeld, D. A., Thrust Force Analysis of Drilling Burr Formation Using Finite Element Method, Proceedings of the 10th International Conference Precision Engineering, Yokohama, Japan, pp. 169-173, 2001. Min, S., Dornfeld, D. A., Kim, J., Shyu, B., Finite Element Modeling of Burr Formation in Metal Cutting, International Journal of Machining Science and Technology, vol. 5, no. 3, pp. 307-322, 2001. Min, S., Modeling of Drilling Burr Formation and Development of Expert System, Ph.D. Dissertation, Department of Mechanical Engineering, University of California, CA, USA, 2001. Min, S., Dornfeld, D. A., Application of Four Levels of Drilling Burr Minimization Strategies, Proceedings of the 2nd Asia-Pacific Forum on Precision Surface Finishing and Deburring Technology, Seoul, Korea, pp. 95-104, 2002. Min, S., Dornfeld, D. A., Nakao, Y., Influence of Exit Surface Angle on Drilling Burr Formation, ASME Trans., Journal of Manufacturing Science and Engineering, Vol. 125, No. 4, pp. 637-644, 2003. Miyake, T., Yamamoto, A., Kitajima, K., Tanaka, Y., Takazawa, K., Study on Mechanism of Burr Formation in Drilling. Deformation of Material during Burr Formation, Journal of the Japan Society of Precision Engineering, vol. 57, no. 3, pp. 485-490, 1991. Miyatani, T., Takazawa, K., Harada, M., Newly Developed Deburring Machines for Precision Parts in Mass Production, SME Technical Paper, MR81-382, 1981.
Montag, A. C., Thermal Deburring: Capabilities and Limitations, SME Technical Paper, MR76-135, 1976. Mller, H., Wagner, T., Thermochemisches Entgraten Gefuegeaenderung, Materialabtrag und Haertebeeinflussung. [Thermochemical Deburring: Structural Changes, Material Removal, and Effect On Hardness], WT Z Ind Fertigung, vol. 65, no. 8, pp. 473-478, 1975. Nakao, Y., Measurement of Drilling Burr by Image Processing Technique, Proceedings of ASPE 16th Annual Meeting, pp. 309-312, 2001. Nakayama K., Arai, M., Burr Formation in Metal Cutting, Annals of the CIRP, vol. 36, no. 1, pp. 3336, 1987. Narayanaswami, R., Dornfeld, D. A., Design and Process Planning Strategies for Burr Minimization and Deburring, Transactions of NAMRI/SME, vol. 28, pp.227-232, 2000, vol. 22, pp. 313-322, 1994. Narayanaswami, R., Dornfeld, D. A., Burr Minimization in Face Milling of Flat Polygonal Parts, ESRC Technical Report #94-23, University of California at Berkeley, October, 1994. Narayanaswami, R., Dornfeld, D. A., A Burr Agent for Precision Manufacturing, ASME IMECE, San Francisco, CA, USA, MED-vol. 2-1, pp. 979-990, 1995. Narayanaswami, R., Dornfeld, D. A., Burr Minimization in Face Milling: A Geometric Approach, Transactions of the ASME, Journal of Manufacturing Science and Engineering, vol. 119, no. 2, pp. 170-177, 1997. N. N., Werkstckkanten, Deutsches Institut fr Normung (DIN), Beuth Verlag Kln Berlin, DIN 6784, 1982. Ohmori, K., Investigations and Studies for Standards of Edge, Iwata Denko Company, Technical Report. Olvera, O., Barrow, G., An Experimental Study of Burr Formation in Square Shoulder Face Milling, International Journal of Machine Tools and Manufacture, vol. 36, no. 9, pp. 1005-1020, 1996. Olvera, O., Barrow, G., Influence of exit angle and tool nose geometry on burr formation in face milling operations, Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture, vol. 212, no. 1, pp. 59-72, 1998. Pande, S., Relekar, H., Investigations on reducing Burr Formation in Drilling, International Journal of Machine Tool Design and Research, vol. 26, no. 3, pp. 339-348, 1986. Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part I, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 221-228, 2000. Park, I. W., Dornfeld, D. A., A Study of Burr Formation Processes using the Finite Element Method: Part II - The Influences of Exit Angle, Rake Angle, and Backup Material on Burr Formation Processes, Transactions of the ASME, Journal of Engineering Materials and Technology, vol. 122, no. 2, pp. 229-237, 2000.
Pekelharing, A. J., Exit Failure in Interrupted Cutting, CIRP Annals, vol. 27, no. 1, pp. 5-10, 1978. Pekelharing, A. J., Exit Failure of Cemented Carbide Face Milling Cutters, Part I Fundamentals and Phenomena, CIRP Annals, vol. 33, no. 1, pp. 47-50, 1984. Ramaswamy, D., Tucker, A., Olmez, A., Chandrasekar, S., Compton, W. D., A Study of the Effect of Process Parameters on Surface Finish of Drilled Holes, Transactions of NAMRI/SME, vol. 28, pp.227-232, 2000. Rangarajan, A., Chu, C. H., Dornfeld, D. A., Avoiding Tool Exit in Planar Milling by Adjusting Width of Cut, Proceeding of the ASME, Manufacturing in Engineering Division, MED-vol. 11, pp. 10171025, 2000. Safranek, W. H., Secrest, A. C., Turn, J. C., Chemical Accelerators for Vibratory Finishing and Deburring of Zinc Die Castings, SME Technical Paper, MR MR76-832, 1976. Safranek, W. H., Secrest, A. C., Turn, J. C., Chemical Accelerators for Vibratory Finishing, Manufacturing Engineering, vol. 77, no. 5, pp. 32-33, 1976. Saunders, L. L., Mauch, C. A., An Exit Burr Model for Drilling Metals, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 123, no. 4, pp. 562-566, 2001. Schaller, Th., Bohn, L., Mayer, J., Schubert, K., Microstructure Grooves with a Width of Less than 50 Pm Cut with Ground Hard Metal Micro End Mills, Precision Engineering, vol. 23, no. 4, pp. 229235, 1999. Schfer, F., Gratbildung und Entgraten beim Umfangsstirnfrsen, VDI-Z 120, Nr. 1 / 2, 1978. Shafer, F., Product Design Influences on Deburring, SME Technical Paper MR75-483, 1975. Shia, C., Stango, R. J., Heinrich, S. M.., Analysis of Contact Mechanics for Circular Filamentary Brush/Workpart System: Part I - Modeling and Formulation, Contact Problems and Surface Interactions in Manufacturing and Tribological Systems, ASME, PED, vol. 67, pp. 171-179, 1993. Shimokura, K., Liu, S., Programming Deburring Robots Based on Human Demonstration with Direct Burr Size Measurement, Proceedings of IEEE International Conference on Robotics and Automation, pp. 572-577, 1994. Sokolowski, A., Narayanaswami, R., Dornfeld, D. A., Prediction of Burr Size using Neural Networks and Fuzzy Logic, Proceedings of Japan-USA Symposium on Flexible Automation, ISCIE, Kobe, Japan, pp. 889-896, 1994. Sonego, R. A., Rotolytic Finsihing, SME Technical Paper, MR89-115, 1989. Spencer, J. D., Cobb, R. C., Dickens, P. M., Surface Finishing Techniques for Rapid Prototyping, SME Technical Paper PE, pp. 1-20, 1993. Stango, R. J., Chen, L., Cariapa, V., Automated Deburring with a Filamentary Brush: Prescribed Burr Geometry, ASME Transactions, Journal of Manufacturing Science and Engineering, vol. 121, no. 3, pp. 385-392, 1999.
Stein, J. M., Dornfeld, D. A., Analysis of the Burs in Drilling Precision Miniature Holes, Proceedings of the 1995 ASME International Mechanical Engineering Congress and Exposition, San Francisco, CA, USA, vol. 2-1, pp. 127-148, 1995. Stein J. M., Dornfeld D. A., Influence of Workpiece Exit Angle on Burr Formation in Drilling Intersecting Holes, Transactions of NAMRI/SME, vol. 24, pp. 39-44, 1996. Stein J. M., Dornfeld, D. A., Burr formation in drilling miniature holes, CIRP Annals, vol. 46, pp. 6366, 1997. Stein, J. M., Dornfeld, D. A., An Architecture for Integrated Design and Manufacturing of Precision Mechanical Components, Transactions of NAMRI/SME, vol. 25, pp 249-254, 1997. Takeyama, H., Kato, S., Burrless Drilling by Means of Ultrasonic Vibration, CIRP Annals, vol. 40, no. 1, pp. 83-86, 1991. Thangaraj, A., Langenstein, M., An Investigation into the Relationship between Hole Quality and Drilling Forces, Proceedings of Manufacturing International 90 Part 4: Advances in Materials and Automation, Atlanta, GA, USA, pp. 149-157, 1990. Yeo, S. H., Ngoi, B. K. A., Chua, L. Y., Ultrasonic deburring, International Journal of Advanced Manufacturing Technology, vol. 13, no. 5, pp. 333-341, 1997.