FORMATION AND
MINIMISATION OF
BURR IN DRILLING
[email protected]
Bhubaneswar
What is a burr?
• Unwanted material
remaining after a
machining operation
• Undesirable projections
of materials beyond the
edge of the work-piece
arising because of plastic
deformation during
machining.
Why remove burr ?
• Accounts for a significant portion of machining costs
• Cause Of Many Industrial Problems.
• Inspection
• Assembly
• Automated Manufacturing Of Precision Components
• Reduce the quality of machined parts
• Can cause interference, jamming and misalignment
• A safety hazard to personnel
•Estimates of between 10% and 30% of the total cost
of a part
•In 1977 estimated cost of deburring $100 million in
Canada alone
Classification of burr
According to height of the burr
•Uniform burr
Type 1-The height of burr varies upto 0.150 mm
Type 2-The height of burr varies in between 0.150 to1.1mm .
Also reffered as transient burr
•Crown burr
Height varies in between 1.1 to 1.5 mm .Burr is not uniform
Uniform burr Type 1 Uniform burr Type 2
Crown burr
According to location of burr,
•Entrance burr
Produced on the side of the work piece where the drill enters
Smaller than the exit burr
Usually of little concern
•Exit burr
Is formed on the opposite side of the work piece
They are more challenging to remove
•Interlayer burr
Drilling Through A Number Of Layers
Entrance burr, Interlayer burr and Exit burr
Mechanism of burr formation
Uniform burr
Small feed force condition this type of burr is formed.
Fracture takes place at the chisel edge
Crown burr
Large feed condition this type of burr is formed
initial rupture will occur at the center
Entrance burr
Material bumped up on the
perimeter of the drill
engaging region
As more part of cutting edge
engages small amount of
bumps of material is always
observed on the perimeter of
the hole
When almost all cutting
edges are engaged, the
shape of bump on the
perimeter starts to change
Interlayer burr
Exit burr
The mechanism of formation of exit burr is same as that of
uniform burr or crown burr depending on feed condition
MINIMIZATION OF BURR
2-Axis Drilling Burr Control Charts
•(DBCC) can be used to predict what
type of burr will be formed given certain
drilling parameters.
•feed rate and thrust force with varying
drill diameters can be approximated by
applying the shear plane model
•Merchant equation, φ = π / 4 + (α-λ) / 2
and the expression for the rake angle
varying with relative radius, R.
•thrust force
•stress that directly influences the burr formation,
•Another important parameter is cutting speed N
•Depending on the cutting speed, the amount of heat generated at
the cutting edge change greatly.
•Finally, the parameters for the chart are:
Pre-drilling and pre-chamfering
Burr minimization through drill tip design
•Gillespie found that increasing helix angle will reduce burr
height by up to 50%, thickness by up to 20%
•Sofronas increase helix angle and harden the exit surface
•by changing the tip of the drill it is possible to minimize the burr
• Plastic deformation region
is formed by the stress
caused by cutting resistance
in the slant section
• The position at which
bending deformation starts is
determined by the rigidity of
the remained part
• When the stiffness of the
part which is bent by thrust
force imposed in drill cutting
edge is large enough, no
bending occurs and cutting is
continued
Observation of burr formation in chamfered drill
Observation of burr formation in round drill
Observation of burr formation in step drill
METHODS OF DEBURRING
Ultrasonic vibration in
drilling
The distribution of the ultrasonic
vibration pressure depends on
•the properties of the medium,
• initial speed,
• density of slurry
• frequency
Results of Ultrasonic vibration in drilling
Before
After
Integrated drilling and deburring tools
Burr off tools:
One-Pass Hole-Deburring tool which can remove both Entrance
and exit burr .Simple and Rugged One-Piece Construction
Allows cutting chips to clear easily
References
• Sung-lim ko1, Jae-eun Chang1 “Development of drill geometry
for burr minimization in drilling”
• P. Stringer, G. Byrne and E. Ahearne “Tool Design For Burr
Removal In Drilling Operations”.
• Jinsoo Kim “Development of a drilling burr control chart for
stainless steel”.
• H. Z. Choi, s. W. Lee, y. J. Choi, s. L. Ko “Study on deburring
technology using Ultrasonic Cavitations”
• Jihong Choi ,Sangkee Min, David A. Dornfeld “Finite Element
Modeling of Burr Formation in Drilling of a Multi-Layered Material”
• Choi, Sangkee Min ,David Dornfeld ,Mahboob Alam, T. Tzong “
Modeling of Inter-Layer Gap Formation in Drilling of a Multi-Layered
MaterialJihong ”
THANK YOU
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