Investigation of Top Burr Formation in Micromilling for Surface Quality Improvement

Kumar, Mohan; Bajpai, Vivek K.

doi:10.1007/s11665-022-07299-x

Cited by 7 publications

(2 citation statements)

References 36 publications

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“…The detachment of some edge burrs can directly impact the performance and lifespan of the machine, and even lead to major safety incidents [2]. Because these defects typically exist at edges, ostia, and similar locations, the conventional methods are challenging to implement [3]. Manual scraping is often used, but the variations in the skill levels of personnel can lead to issues such as unstable processing quality and high scrap rates [4].…”

Section: Introductionmentioning

confidence: 99%

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Zou,

Ying,

et al. 2024

Surf. Sci. Tech.

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Magnetic needle grinding processing technology is one of the magnetic grinding processing techniques. It possesses the characteristics of micro-cutting removal, small increase in processing temperature, flexible processing, high-quality, and high-precision processing. It is mainly utilized to remove burrs at the edge of the workpiece and the edge of the hole, as well as to finish the surface of the workpiece. It is frequently employed in civil, aerospace, navigation, and other fields. Due to the randomness and complexity of magnetic needle movement in magnetic abrasive finishing, it is difficult to quantify the processing parameters and predict processing effects. Therefore, this paper establishes a simulation model of magnetic needle in magnetic abrasive finishing by the coupling numerical simulation method of fluid dynamics discrete element method (CFD-DEM) to analyze the working state parameters of the magnetic needle. Through the simulation of actual working conditions, the machining process and parameters of magnetic abrasive finishing are quantified and analyzed, and the motion trend of magnetic needles during the machining process is studied. Then, the residual stress of single magnetic needle impact is analyzed with ABAQUS, and the performance enhancement of the workpiece is predicted. Finally, observations of surface morphology and validation of residual stress prediction were conducted through experiments on an aluminum plate. The results show that the residual stress of the aluminum plate is positively correlated with the number of strikes of the magnetic needle. The residual stress changes from tensile stress (+0.1 MPa) to compressive stress (-16.5 MPa). The comparison between simulation results and experimental results is good, indicating that the simulation model can comprehensively consider multiple factors such as magnetic field, particle motion, and fluid flow, and establish a magnetic needle magnetic grinding process model that is suitable for actual working conditions.

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Section: Introductionmentioning

confidence: 99%

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Zou,

Ying,

et al. 2024

Surf. Sci. Tech.

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“…Recently, for the effort of investigating the burrs formation mechanism in milling of thin-walled workpiece, a lot of works have explored [8][9][10]. Burrs generate due to the plastic deformation and flow of aluminum alloy on the entrances and exits of cutting tool on workpiece surface in milling [11], then, micro-burr formation mechanisms and different burrs types (shown in Fig.…”

Section: Introductionmentioning

confidence: 99%

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

Wang¹,

Zhao²,

Zhang³

et al. 2023

Preprint

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In aviation and weapon industry, aluminum alloy thin-walled workpiece are widely used, and milling is a common manufacturing process for these thin-walled workpiece. In milling, many burrs generate on the entrances and exits of cutting tool on workpiece surface, which affects machining quality, assembly accuracy and produces more seriously tip discharge effect. To investigate the burr formation mechanism, an analyzed model of top burr thickness considering the tool deflection angle and workpiece deformation is proposed to elaborate the burr formation process in milling of thin-walled workpiece. In this process, top burr formation process is analyzed and the burr thickness is expressed by the motion relationship between cutting tools and workpieces. Then, based on energy theory, a top burr thickness predicted model considering the tool deflection angle and workpiece deformation in milling of aluminum alloy thin-walled workpiece is proposed. Subsequently, under the determined milling condition, the top burr thicknesses are calculated for verification. Finally, several milling experiments are carried out for validating the feasibility and effectiveness of the proposed model. Experimental results show that the predicted top burr thicknesses are in good agreement with the measured value in milling, and the prediction accuracy of the top burr thickness by proposed model reached 96.5%.

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Effectiveness of Quantum Computing in Image Processing for Burr Detection

Merino-Bajo,

Sánchez-González,

Riego

et al. 2023

Lecture Notes in Networks and Systems

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Investigation of Top Burr Formation in Micromilling for Surface Quality Improvement

Cited by 7 publications

References 36 publications

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

Effectiveness of Quantum Computing in Image Processing for Burr Detection

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