Satish Kumar
Sponsored
By: CODEF/NSF
Abstract
Analysis of burr formation in the milling process involves numerous factors. It can be
divided into two major categories: geometric factors and material properties. This study
presents the impact of geometrical factors in face milling process and accordingly
predicts the location of burr formation. It also ranks different kinds of burr formation
during the process. A unified criterion has been identified to analyze burr formation for
different tool engagement. It exploits the exit order of cutting edges of the tool along the
workpiece edge, which essentially include the three-dimensional nature of the process. It
correlates the cutting mechanism and burr formation by using Exit Order Sequence as an
approximation of chip flow angle. Impacts of different possible Exit Order Sequence on
burr formation were analyzed. Previously observed phenomenons were explained based
on Exit Order Sequence. Experiments were done on real parts used in the production line
of Daimler-Chrysler to verify the concept. Results of the experiment were satisfactory.
Also basic experiments were done with three different materials to analyze the impact of
material property on burr formation for set of Exit Order
Sequences.
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