Burr formation

Another problem of the microscale is the surface quality of the single parts of a device. Burr formation generated by mechanical micromachining or laser machining... 

Burrs are an economically very important issue in many machining operations. Therefore, a lot of research has been done in the last 50 years to understand, control, and minimize burr formation. The first published works on burrs cover... 

To gain a better understanding of the burr formation process and to be able to predict burr formation, the finite element method analysis can be applied. In Leopold et al. (2005), the state of research and future developments in modeling and simulation of burr formation are highlighted. 

Leopold J, Schmidt G, Hoyer K, Freitag A (2005) Modelling and simulation of burr formation state-of-the-art and future trends. In Proceedings of the 8th international workshop on modeling of machining operations, Zwickau Verlag Wissenschaftliche Scripten (Berichte aus dem IWU) pp 73-83... 

Influence of Cutting Edge Radius on Burr Formation... 

Cutting Edge Influence on Machining Titanium Alloy, Fig. 12 Burr formation when milling Ti-6A1 V with... 

For the drilling process, four main quality aspects have to be considered burr formation, dimension of bore, roughness, and errors in form. The drill milling leads in general to a lower burr formation... 

Furthermore, the demands on the bore quality are very high regarding dimensional accuracy and burr formation as well as delamination of the CFRP layers (Dege 2012). 

The drill milling process leads to a low burr formation and a low delamination of the CFRP layers (Brinksmeieretal. 2008). Furthermore, the produced chips are small compared to conventional drilling processes. Because the bore diameter is bigger than the tool diameter, the chips can be evacuated easily. In conventional drilling, the chip transport in the flutes of the tool leads to friction at the wall of the borehole. Especially when the CFRP layer is machined prior to the titanium or aluminum layer, the hot chips of the metallic material can destroy the surface in the CFRP layer. This can be avoided using the drill milling process. 

Burr formation can also be shown to be dependent on cutting speed in some cases. Studies on high speed machining show a reduction in burrs as cutting speed increases (Aurich et al. 2009) while sometimes distinct minima in burr formations were found. 

Aramcharoen A, Mativenga PT (2009) Size effect and tool geometry in micro milling of tool. Precis Eng 33(4) 402-407. doi 10.1016/j.piecisioneng.2(X)8.11. (X)2 Lee K, Domfeld DA (2002) An experimental study on burr formation in micro milling aluminium and copper. Trans NAMRl/SME 30 255-262 Masuzawa T (2000) State of the art of micromachining. 

On the microscale, burr formation generated by mechanical micromachining or laser machining may lead to significant problems with the assembly of device parts and also vfith the bonding. Therefore, special attention has to be paid to burr microstructures or to avoid burr formation. 

Guo, Y.B. and Dornfeld, D.A. (2000) Einite element modeling of drilling burr formation process in drilling 304 stainless steel, ASME Journal of Manufacturing Science and Engineering, 122(4) 612-19. 

Kim, J., Min, S. and Dornfeld, D.A. (2001) Optimization and control of drilling burr formation of AISI 304L and AISI 4118 based on drilling burr control charts. International Journal of Machine Tools and Manufacture, 41 923-36. 

Ko, S.L. and Lee, J. (2001) Analysis on burr formation in drilling with new concept drill, Journal of Materials Processing Technology, 113 392-S. 

Min, S., Dornfeld, D.A., Kim, J. and Shyu, B. (2001a) Finite element modeling of burr formation in metal cutting. Machining Science and Technology, 5(2) 307-22. 

Stein, J.M. and Dornfeld, D.A. (1997) Burr formation in drilling miniature holes. Annals ofCIRP, 46(1) 63-6. 

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