Burr Formation in Drilling Intersecting Holes

Leitz, Lukas; Franke, Vikki; Aurich, Jan C.

doi:10.1007/978-3-642-00568-8_11

Cited by 5 publications

(5 citation statements)

References 2 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Leitz develops two kinematical process models describing tool exit and entry conditions, as well as the calculation of remaining material when drilling intersecting holes. The combination of these process models and experimental results enables well funded declarations on burr position and shape depending on intersection geometry [96].…”

Section: Mechanics Of Burr Formation/analytical Modelsmentioning

confidence: 99%

Burrs—Analysis, control and removal

et al. 2009

Self Cite

View full text Add to dashboard Cite

Section: Mechanics Of Burr Formation/analytical Modelsmentioning

confidence: 99%

Burrs—Analysis, control and removal

et al. 2009

Self Cite

View full text Add to dashboard Cite

“…A reduction in feed rate likewise increases the predictability of the initial breakthrough position and hence the behavior of the chip formation. Lower feed rates and higher inclination angles of the exit surface will provide fewer burrs; this is also supported by Leitz, Franke, and Aurich [19] that build upon an earlier model developed by Min [20]. Figure 6 illustrates two exit surfaces with different slope angles.…”

Section: Burr Formationmentioning

confidence: 55%

Strategies for Effective Chip Management in Machining of Ductile Cast Iron

Jönsson,

Aliboni,

Windmark

et al. 2024

Advances in Transdisciplinary Engineering

View full text Add to dashboard Cite

A continuously growing and mutating market with increasing demands on environmental sustainability, illuminated by unraveling environmental threats, highlights the need for greater resource efficiency in modern manufacturing industries. Machining has become pivotal in the pursuit of sustainability given its superior efficiency in manufacturing of metallic products. In theory, the efficiency of a machining operation is dictated by the material removal rate and chip formation behavior. However, this may also present additional challenges as chips can be difficult to evacuate from the workpiece, and cause chip carryover. Chip management aims to contain manufacturing costs by addressing this issue and simultaneously pursuing higher machining efficiency. Persistent chips trapped in internal cavities is particularly challenging and can affect quality, and result in costly re-manufacturing, scrapping of portions of produced volume. Effective chip management strategies is therefore crucial to avoid these problems. While there is established research on machining theory and chip removal, proposed solutions are often focused on a specific implementation and lack a holistic perspective on the phenomenon. This study aims to fill this gap in the knowledge by providing a strategic and practical application to tie together information that would otherwise be disaggregated. A case study was conducted to investigate the role of machining, and identify the source of chip carryover and its effect on subsequent production stages. Practical verification demonstrated the effectiveness of the proposed interventions in reducing production costs by decreasing the cycle time and reducing waste, and improving product quality. The future of sustainable manufacturing processes relies on the adoption of strategies and interventions that contribute to the efficiency and sustainability of the manufacturing industry. This study provides a valuable contribution to this effort.

show abstract

“…In the majority of drilling operations, burrs will form as the drill enters and exits the part. In a study of German automotive and machine tool industries, Leitz, Aurich, and Franke [28] focused on costs associated with burr minimization, deburring, and part cleaning. Their findings revealed that burrs cause an increase of about 15% in manpower and cycle-time expense, a 2% share in the rejection rate and a 4% share in machine breakdown times.…”

Section: Deburring Processesmentioning

confidence: 99%

Drilling Burr Formation With Tool Wear

Mandra¹

2021

Preprint

View full text Add to dashboard Cite

Automated assembly processes are being widely used in aircraft manufacturing as a hole must be drilled before fastener installation. Burr formation is of importance for machining processes including drilling. A burr, an unwanted by‐product of machining, is a raised edge that remains attached to a workpiece because of the loss of shear action. In drilling, burrs form as the drill enters and exits the part, particularly when the tool becomes worn. Burrs require an additional process to deburr, incurring extra cost and time. To understand drilling burr formation, this dissertation presents a new model that combines a burr model with a tool‐wear model. The first adopted model describes a burr with respect to its height and thickness and relates burr formation to the drilling thrust force generated from drilling with a sharp tool. This model comprises a number of key factors: part material property, tool geometry, and drilling parameters. In reality, these factors will vary. Preliminary work was done to use this model to develop a sensitivity matrix for the purpose of studying the effect of variation in the key factors on burr formation. Unfortunately, tool wear, which is a major issue, cannot be simply considered as a variation in tool geometry. When a tool becomes worn, the cutting edge radius becomes large, and the cutting action changes from shearing to ploughing. A second model adopted is a tool wear model, leading to the core work of this dissertation. The aim of this study is to develop a drilling burr‐formation model for realistic conditions, incorporating variance within the tool and process parameters. The proposed method applies a weighting model that can consider the wear/no‐wear condition for each segment, thereby leading to a hybrid model for drilling burr formation. The research method is validated through simulation and an experiment entailing the generation of drilling burrs in conditions mimicking those in aerospace manufacturing. The results show that the model successfully estimates burr height and thickness trends with increasing levels of tool wear, for penetrated holes. The methods and results presented in this dissertation show good promise for understanding the effects of tool wear on drilling burr growth.

show abstract

Burr Formation in Drilling Intersecting Holes

Cited by 5 publications

References 2 publications

Burrs—Analysis, control and removal

Burrs—Analysis, control and removal

Strategies for Effective Chip Management in Machining of Ductile Cast Iron

Drilling Burr Formation With Tool Wear

Contact Info

Product

Resources

About