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Conventional Drilling
• Introduction
• Effects of Burr
• Types of Burrs
• Mechanism of burr formation
• Minimization of Burr
• Methods Of Deburring
By:
Soumya mahapatra
(soumya_00457@yahoo.co.in)
Uniform burr
Uniform burrs are burrs whose height varies in between
1.1mm.Further it is classified into type 1 and type 2 .The
height of type 1 burr varies in between 0.150 mm and that of
type 2 is between 0.150 to1.1mm.The height of the burr is
more uniform in this type of burr.
Crown burr
Crown burrs are burrs whose height varies in between
1.1 to 1.5 mm. The height of the burr is not uniform in this
type of burr.
According to location of burr, there are three types of burr
• Entrance burr
• Interlayer burr
• Exit burr
Entrance burr
The entrance burr is produced on the side of the work piece
where the drill enters; this burr is usually considerably smaller
than the exit burr and is usually of little concern as it may be
removed easily by chamfering the hole.
Exit burr
The exit burr is formed on the opposite side of the work
piece as the drill breaks through. These burrs are usually more
substantial than the entrance burr, and as they are on the
opposite side of the work piece to the machine, they are more
challenging to remove. They can also be located within a
cavity in the work piece where there is no access to the exit
side of the hole
Interlayer burr
When drilling through a number of layers, interlayer burrs
are often formed between the layers. In certain circumstances
these burrs must be removed. In order to do this, it may be
necessary to dismantle the parts to remove the burrs
Two burrs are produced in the drilling of every hole;
entrance and exit burr
Uniform Burr
As the drill approaches the exit surface, the material under
the chisel edge begins to deform. The distance from the exit
surface to the point where the deformation starts depends on
the thrust force of the drill. As the drill advances, the plastic
deformation zone expands from the center to the edge of the
drill. At the final steps, the remaining material is bent and
pushed out to form a uniform burr with a drill cap. Here the
fracture takes place at the chisel edge. Type 1 and type 2
uniform burr formation has same mechanism. Under small
feed force condition this type of burr is formed.
Crown Burr
A larger
thrust
force
induces
plastic deformation earlier in the process, making the thicker
material layer ahead of the drill undergo plastic deformation,
inducing a larger maximum stress on the exit surface. As a
result, initial rupture will occur at the center. The remaining
material is then bent and pushed out without being cut to
form a relatively large burr
Exit burr
As it can be said that
uniform burr and crown
burr are two types of exit
burr so the mechanism
of formation of exit burr
is same as that of
uniform burr or crown
burr depending on feed
condition.
Entrance Burr
At the beginning of
drilling process, material
bumped up on the
perimeter of the drill-
engaging region because
of the indenting action of
the drill bit. As more part
of cutting edge engages
in machining, hole
diameter becomes larger
and before all the cutting
edge is engaged in the
machining, small amount
of bumps of material is
always observed on the
perimeter of the hole (t
= 1.5 ~ 1.875 sec in).
When almost all cutting edges are engaged, the shape of
bump on the perimeter starts to change from a smooth, round
shape to a biased, shaper shape (t = 2.125). Finally, as all drill
bit engages, i.e. drill completely penetrates through the first
layer; entrance burr remains on the surface. (t = 2.25 ~ 2.625
sec). The shape of remaining burr is uniform around the hole
and slightly bent outward of the hole.
Interlayer Burr
The formation of inter-layer burr is shown in Figure. They
depend on the combination of the upper and the lower
materials, the thickness of
the sealant between layers
and the process
parameters. Here two
plates are being drilled is
shown in the figure at
different instant. Until
around 0.7 second, two
plates bend elastically and
no gap between the two
layers is observed. Axial
displacement of the
observing nodes increases
almost linearly up to 0.34
mm. No material failure
occurs in this stage. Plastic
deformation is limited near
the area around the drill tip
engaged to the drilling. At
around 0.7 second, the
displacement of the
observing nodes falls down
to 0.13 mm and a small gap
starts to form and increases
as the drill advances.
Material starts to fail
around the drill tip area and
element elimination starts
to occur at this stage. Drill
bit starts to engage the
second layer at around t = 2.6 second. Interlayer gap starts to
increase significantly as the first layer starts to spring back
and the second layer is pushed toward feed direction by the
drill bit. Inter-layer gap reaches the maximum at around t =
4.5second and starts to decrease as the second layer starts to
spring back as the plastic deformation of outer surface
increases. From around t = 5.5 second, the displacement of
the node on the entrance surface of the second layer (node 2)
starts to go below that of the node on the exit surface of the
first layer (node 1).This means that the second layer touches
previously formed inter-layer burr.
Typical inter-layer burrs are shown in Figure. In general, as
the drill moves downwards, a large exit burr forms at the exit
surface of the upper material and a small entrance burr forms
MINI MI ZA TI ON OF BURR
As we see that the presence of burr in metals has many ill
effects so different methods are used to minimize the burr.
Some of them are being discussed.
2-Axis Drilling Burr Control Charts
Drilling Burr Control Charts (DBCC) can be used to predict
what type of burr will be formed given certain drilling
parameters, this can be used
to minimize burr or to alter
the type of burr produced.
The first parameter of the
chart is related to the feed
rate and drill diameter. The
thrust force directly affects
the amount of the plastic
deformation of the material
at the final stage of the
drilling process, and as a
result, influences burr
formation. It is known that
increase in the feed rate in
drilling tends to increase the thrust force. Correlation between
feed rate and thrust force with varying drill diameters can be
approximated by applying the shear plane model to the
drilling process
Figure shows the shear plane model applied to a fraction of
the cutting edge of a drill. Together with the Merchant
equation,
φ = π / 4 + (α-l) / 2,
and the expression for the rake angle varying with relative
radius, R. we can calculate the thrust force that is exerted on a
fraction of the cutting edge. Finally total thrust force can be
expressed as:
Where, k is the shear strength of material, f is feed rate
(mm/rev), h is the helix angle, 2κ is the point angle of the drill
and t is the ratio of web thickness to the drill diameter. Since
it is stress that directly influences the burr formation, an
effective stress is considered and can be represented as the
following.
• A number of tool
companies have
developed integrated
drilling and deburring
tools which are capable
of first drilling a hole
and then removing any burr which is formed. These
tools work for holes with a diameter greater than 9.5
mm . An example of one of these tools can be seen in
Fig below.
• Burroff tools: One-
Pass Hole-Deburring
tool which can remove
both Entrance and exit
burr
How it works
1. Integral cutting
edges remove the burr
from the front of the hole
as the tool enters the
hole.