MINIMIZATION OF BURR IN DRILLING Under The Guidance of Prof. N. S.

Das

Objective of Project To become familiar with burr formation in drilling To study the variation height s of burr in drilling of Aluminum and Mild Steel workpieces with different feed, spindle speed for and three different diameters

Backgrou nd Burrs are defined as undesirable projections of materials beyond the edge of the workpiece arising due to plastic deformation during machining. Burrs can cause many problems during inspection, assembly, and automated manufacturing of precis ion components. Therefore, it is desirable for precision parts to be free from b urr. This project considers burr assessment in drilling operations.

Experimental Parameters The burr height depends on many variables. They are: Drill Geometry, Drill Sharp ness, Drill Diameter Drill machine conditions Vibration and Deflection Work mate rial geometry and its properties Drilling Conditions Spindle speed and Feed Cutt ing Fluid composition, flow rate and method of the effect For this projectapplic ationof feed, spindle speed, drill diameter and work material will be used as in put parameters

Scope of our Project

 Aluminum alloy (bright aluminum) blocks of size 60mm x 30mm x 16mm. Materi als Mild steel blocks of size 60mm x 30mm x 16mm

 R. K. Engineering Radial Drilling machine with 2HP. The drilling machine allows three discrete variations in the spindle speed and three discrete variations in feed. High speed steel (HSS) drill bits of diameter 6mm, 8mm and 10 mm Machine tool and Tools

 Meter M Horizontal Floor Profilometers with 10 x lens, 20x lens, 50x lens, Magni fication accuracy 0.1% and surface 0.15%, with least count of 0.01 mm Measuring Instruments

Experimental Procedure Determine the spindle speed and feed rate at different settings of the drilling machine Drill holes in both Aluminum and Mild Steel work pieces with all combina tions of feed, spindle speed and diameter Determine the heights of burr using Pr ofilometer Record the observations and plot the graphs

Determination of spindle speed and feed rate The drilling machine allows three discrete variations in the spindle speed and t hree corresponding discrete variations in the feed But the values of these feed and spindle speed are measured individually and has been

SPINDLE SPEED MEASUREMENT: Fix a counter sunk shaft in the drill spindle Values of spindle speed are measur ed with the help of a Tachometer

FEED MEASUREMENT: Feed values are measured by recording the distance traversed using graduations o n the quill Time to move a certain distance for all the feeds are recorded using a stop watch And finally the feed is

 Three holes are drilled in each block with same spindle speed & diameter and thr ee different feed rates. This process was repeated for other two spindle speeds and other drill diameters also To drill holes in work pieces

 To determine the burr height The Profilometer enlarges a two dimensional shadow of the work piece on the projection screen Work piece kept on the table is moved by rotating the micrometer so that the cro ss hair line moves from metal surface to highest tip of the burr Burr height is the difference between

Burr Observed in Drilling Process The Results obtained from Profilometer are tabulated and then plotted graphicall y for easier interpretation and understanding BURR HEIGHT VS FEED: These graphs show the burr height against feed for differen t values of RPM for both Aluminum and Mild Steel for all three diameters EFFECT OF DRILL DIAMETER: These graphs helps us in comparing how burr height is influen ced by Drill diameter EFFECT OF WORK MATERIAL: These graphs helps us in comparin g how burr height is influenced by work material and its

Burr Height vs. Feed The first set of graphs plotted are Burr Height against Feed for different value s of RPM for both Aluminum and Mild Steel for all three diameters So there are t hree graphs each for Aluminum and Mild Steel (one for each diameter 6mm , 8mm, a nd 10mm)

 Aluminum, 6mm diameter

 Aluminum, 8mm diameter.

 Aluminum, 10mm diameter.

 Mild Steel ,6mm diameter.

 Mild Steel, 8mm diameter.

 Mild Steel, 10mm diameter.

 These graphs plot burr height against nine different combinations of feed and RP M for each Drill diameter. So there are two graphs one each for Aluminum and Mil d Steel These graphs help us in comparing how burr height is influenced by Drill diameter Effect Of Drill Diameter

 Aluminum

 Mild Steel

Effect of Work Material These graphs plot burr height against nine different combinations of feed and RP M for each Work material So we will three graphs one for each Drill diameter The se graphs helps us in comparing how burr height is influenced by Work material

 Drill diameter 6mm

 Drill diameter 8mm

 Drill diameter 10mm

FEED vs. BURR HEIGHT Conclusi on The first three graphs are of aluminum we observed that at low rpm on increase o f feed rate, the burr height increases We further observed that at medium rpm on increase of feed, burr height tends to a constant value At highest rpm there is no such pattern The same pattern can be observed in mild steel but with a few e xceptions

EFFECT OF DRILL DIAMETER ON BURR HEIGHT In aluminum we observed that the average burr height is maximum with 8mm drill w hereas in mild steel 6mm drill gives the largest burr Conclusions contd.. EFFECT OF WORK MATERIAL ON BURR HEIGHT We observed that in the two graphs of 8mm and 10mm drill diameter, the burr heig hts of aluminum is less compared to mild steel.

 A burr is a plastically deformed material that remained on the work piece after machining Introduct ion