Research Papers

Analysis and Modeling of Burr Formation During the Plane Milling of Cast Aluminum Alloy Using Polycrystalline Diamond Tools

[+] Author and Article Information
Clément Bourlet, Guillaume Fromentin

Arts et Metiers ParisTech,
Rue Porte de Paris,
Cluny 71250, France

Elias Harika, Arnaud Crolet

3 Rue de Nogent,
Laigneville 60290, France

Manuscript received August 4, 2015; final manuscript received December 22, 2015; published online April 21, 2016. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 138(8), 081010 (Apr 21, 2016) (12 pages) Paper No: MANU-15-1390; doi: 10.1115/1.4032584 History: Received August 04, 2015; Revised December 22, 2015

Burr formation is a significant problem during manufacturing and leads to a lack of geometrical quality through the appearance of undesired and undefined shapes on the workpiece. Thus, understanding the burr formation and elaborating of predictive models are helpful for process design in order to avoid or to reduce burrs and to optimize the strategies for eventual deburring. This study presents both an experimental approach and a model for the plane milling of openwork parts, where burrs are a significant factor. A large-scale analysis of relevant geometrical parameters and their interactions are performed. A phenomenological burr size model is established considering local parameters and the specificities of 3D cutting in milling. Based on local parameters, this article proposes a new methodology to simulate burr height along any part edge and for most face-milling trajectories. Simulations and validations during tool path exits, with changing local parameters, are presented. In addition to the quantitative approach, new 3D aspects of face milling in relation with exit order sequence (EOS) are developed.

Copyright © 2016 by ASME
Topics: Cutting , Milling , Wedges , Modeling
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Fig. 1

Effect of EOS on bottom burr size [18]

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Fig. 2

Bottom burr types during face milling

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Fig. 3

Milling cutter and insert characteristics

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Fig. 4

Geometrical and kinematic parameters definition in end milling

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Fig. 5

Observations of burr type and entry/exit effect in full face milling

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Fig. 6

Burr height measurement methodology with mechanical profilometer

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Fig. 7

Effect of the depth of cut on burr height: Vc = 2500 m/min, fz = 0.25 mm · rev−1· th−1, Φe = −48.6 deg, and Δ = 90 deg

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Fig. 8

Effect of opposite cutting edge exit angle on burr height: Vc = 2500 m/min, fz = 0.25 mm.rev −1.th−1, ap = 1 mm, and Δ = 90 deg

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Fig. 9

EOS determination considering workpiece wedge angle Δ

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Fig. 10

Workpiece geometry to study the effect of the wedge angle

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Fig. 11

Effect of workpiece wedge angle on burrs height: Vc = 2500 m/min, fz = 0.25 mm.rev −1.th−1, ap = 1 mm, and Φe = 0 deg

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Fig. 12

Effects and interactions of parameters on burr height

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Fig. 13

EOS during tool exit path for three simulations Ψϵ {60 deg, 90 deg, 120 deg}

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Fig. 14

Uncut chip thickness at the cutting edge exit hex (a) and cutting edge exit angle ϕe (b) during the three simulations Ψ ϵ {60 deg, 90 deg, 120 deg}: fz = 0.25 mm.rev−1.th−1 and ae = D

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Fig. 15

Variation in burr height along workpiece boundary: experimental (points) versus simulations (curves): Ψϵ {60 deg, 90 deg, 120 deg}, Vc = 2500 m/min, fz = 0.25 mm.rev−1.th−1, ap = 2 mm, ae = D, and Δ = 90 deg




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