SYS 849 5 Lecture Burr Deburring and Edge Finishing

2014-05-30
Surface Treatment, Finishing and Integrity:

Special Case of Machined Edge Finishing
Burr and Deburring
Dr. Seyed Ali Niknam
Laboratory of Products, Processes and Systems Engineering (LPPSE)
Department of Mechanical Engineering
cole de technologie suprieure (ETS)

June 3th 2014
Course outline
1. Burr definition
2. Burr formation mechanism, shapes and classifications
3. Factors governing burr formation
4. Burr size minimization/optimization

5. Burr formation/size modeling
6. Burr measurement and detection methods
7. Burr removal (deburring) and edge finishing

Niknam, Seyed Ali June 3rd 2014
2014-05-30
1.Burr definition
Burr definition
A burr is a extended body over the workpiece surface.
Turning burrs
Definition of burrs according to ISO 13175
b) Large burr formation
Exit burrs observed when Drilling Al 6061-T6

Zedan et al., Machining & Machinability of Materials, 2012
b) Limited & non visible burr
Slot milling burrs

Niknam and Songmene., Journal of Engineering and Manufacture, 2013
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A Short History of the Burr

Metal burrs first appeared ~3000 B.C. (5000 years ago) at the
beginning of the Bronze Age (in Thailand as well as in
Mediterranean area)
Burrs in iron and steel appear first about 1000 B.C. (3000
years ago).
Source: Gillespie, in Proc. 7th Intl Conf. on Deburring and Surface Conditioning, UC-Berkeley, 2004
Burr Formation Studies

1958 Keiji Okushima - First publisher of burr
formation mechanics
Source: Gillespie, in Proc. 7th Intl Conf. on Deburring and Surface Conditioning, UC-Berkeley, 2004
2014-05-30
Why are we interested to burrs ?

Burrs are everywhere
there is an edge!
Source:(Aurich et al, CIRP Annals, 2009)

Burrs are everywhere
there is an edge!
2014-05-30

Their presence :
1. Represents 30% of the finishing cost of the component;
2. Reduces the quality of components in an assembly;
3. Causes injury to workers during handling (Gillespie, 1999);
4. Is the main reason for tool change in milling of aluminium alloys(Lee, 2004)
Category of expenses due to presence of burr
Source: (Aurich et al, CIRP Annals, 2009)
Breakdown of manufacturing
expenses (Bosch)
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2. Burr formation mechanism, shapes

and classifications
Burr formation mechanism
Burr/breakout formation model:

(a) initiation, (b) development and (c) final burr formation
Source: (Niknam, Ph.D thesis, ETS, 2013)
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Burr formation mechanism
Source:(Hashimura, et al., ASME Manufacturing journal , 1999)
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Burr formation process
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Burr Formation Sequence in Al2024-O

(SEM Images)
Source: Laboratory for Manufacturing and Sustainability, UC-Berekley
15
Edge Quality Standard

Theoretical workpiece edge
Burr
Burr
Burr
(Gillespie, Journal of Manufacturing Engineering, 1996)
Source: (Aurich et al, CIRP Annals, 2009)
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Measurement values of burr
Source: (Schfer, 1975)
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Various Types of Burrs in Machining
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Advanced Cutting Mechanics: Milling

One of the most versatile processes available.
3D effects become very important!
Source: www.mmsonline.com
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Advanced Cutting Mechanics: Milling

Milling terms/conventions
Source: www.mmsonline.com
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Types of Burrs in Milling
Face milling burrs
Slot milling burrs
Source: (Lee, Ph.D thesis, UC-Berekley, 2004)
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Milling burr classification
Source: (Nakayama, Arai, CIRP Annals, 1987)
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Milling burr classification-Location
23
Milling burr classification-Shape
Source:(Hashimura, et al., ASME Manufacturing journal , 1999); (Chern, Ph.D thesis, UC-Berekley,1993)
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Milling burr classification-Classification
Source:(Hashimura, et al., ASME Manufacturing journal , 1999); (Kishimoto et al., Bull. Jpn. Soc. Precis. Eng, 1981)
25
Milling burr classification-Example
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Drilling Burr formation mechanism
27
Drilling Burr Mechanism
2009 Laboratory for Manufacturing and Sustainability, UC-Berekley
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Drilling burr formation
Source: R. Furness, Ford
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Drilling Burr Classification
Source: (Kim, Journal of Engineering materials and technology, 2000)
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Burr Formation in Intersecting Holes

Problems:
Limited accessibility of the burr
Burr not tolerable in flow-through areas
DaimlerChrysler AG
31
Burr Formation in Intersecting Hole
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Geometry Variation in Intersecting Holes
33
Comparison of burr shapes
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3. Factors governing burr formation
35
Factors governing burr formation
Source:(Aurich et al.,CIRP Annals, 2009)
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Critical Factors governing burr formation

1.
Machined part (geometry, dimension, mechanical properties, etc.)
2.
Cutting parameters (cutting speed, feed rate, depth of cut, etc.)
3.
Cutting tool (material, shape, geometry, rake angle, lead angle, helix angle, etc.)
4.
Machine tool (rotational speed, dynamic strength, etc.)
5.
Manufacturing strategy (tool path, coolant, back cutting, lubrication condition ,etc.)
6.
Other parameters (e.g. cutting forces)

This summary is still inadequate due to complex interaction effects between process
parameters
The factors governing milling burrs can not be separated to Direct and Indirect factors
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37
Other governing factors on burr formation

Built-Up Edge, or BUE (layers of welded work
material) may form at the tip of the tool.
Especially prevalent in machining of aluminum.
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Other governing factors on burr formation

Tool Wear
Source:(Schey, McGraw-Hill, 1987)
39
Tool Wear
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Grain boundary effects
41
Edge radius effects
Conventional cutting
Micro cutting
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Case study 1
Investigation of factors governing
slot milling burr formation
By
Seyed Ali Niknam and Victor Songmene
Published in
Journal of Engineering and Manufacture in March 2013
Main objective
Statistical tools and experimental study are used to determine the dominant
cutting parameters on burrs size (height and thickness) during slot milling of
AA 2024-T351 and AA 6061-T6
List
Burr name
B1
Exit up milling side
B2
Exit bottom bur
B3
Exit down milling side burr
B4
Top down milling burr
B5
Top up milling burr
B6
Entrance bottom burr
B7
Entrance up milling side burr
B8
Top up milling burr
Niknam and Songmene, Journal of Engineering and Manufacture, 2013
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Main objective
Statistical tools and experimental study are used to determine the dominant
cutting parameters on burrs size (height and thickness) during slot milling of
AA 2024-T351 and AA 6061-T6
List
Burr name
B1
Exit up milling side
B2
Exit bottom bur
B3
Exit down milling side burr
B4
Top down milling burr
B5
Top up milling burr
B6
Entrance bottom burr
B7
Entrance up milling side burr
B8
Top up milling burr

45
45
Experimental procedure
3 Axes Machining Center
Profilometer for surface roughness

measurement
Cutting trials configuration
Optical microscope for burr size measurement
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Burrs geometrical description
Most of existing research works characterized the burr height.

From a deburring perspective, the burr thickness is of interest.
Burr thickness describes the time and method necessary for deburring a workpiece.

47
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Experimental Plan
Experimental parameters
Level
A: Material
B: Tool
Coating
Insert nose radius, Re (mm)
C: Depth of cut (mm)

D: Feed per tooth (mm/z)
E: Cutting speed (m/min)
AA 6061-T6
AA 2024-T351
TiCN
TiAlN
TiCN+Al2O3+TiN
0.5
0.83
0.5
0.01
0.055
0.1
300
750
1200
Lubrication condition: Dry
The statistical terms and techniques used:

1. ANOVA ; 2. Pareto Analysis; 3.Main effect plot ; 4. Interaction effect
analysis; 5. Regression model
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Milling exit burrs

1. B2 burr is formed by a loss of material from B1 burr
2. Transition from primary to secondary burr formation is observed
3. Larger Re leads to primary B2 burr where the depth of cut is smaller than
the Re or very close to it.

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Exit up milling side burr (B1)
Pareto Chart for SG t
Pareto Chart for SG
BC
D:Feed
CD
DE
A:Material
C:Depth
CE
B:Tool
BE
AE
BD
E:Speed
AB
DD
EE
AC
AD
Sig. at 5%
Not sig.
B1 Height
4
6
8
10
Contribution to variation (%)
12
D:Feed
C:Depth
B:Tool
BC
BD
E:Speed
AE
EE
DE
AB
A:Material
AD
BE
DD
CE
AC
CD
Sig. at 5%
Not sig.
B1 Thickness
Very sensitive to cutting
parameters
10
20
30
40
50
50
50
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Exit up milling side burr (B1)

Pareto Chart for SG t
Pareto Chart for SG
BC
D:Feed
CD
DE
A:Material
C:Depth
CE
B:Tool
BE
AE
BD
E:Speed
AB
DD
EE
AC
AD
Sig. at 5%
Not sig.
B1 Height
4
6
8
10
12
D:Feed
C:Depth
B:Tool
BC
BD
E:Speed
AE
EE
DE
AB
A:Material
AD
BE
DD
CE
AC
CD
Sig. at 5%
Not sig.
B1 Thickness
Very sensitive to
cutting parameters
10
20
30
40
50
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Interaction effect plots
Similar Procedure has been used when analyzing the top and entrance burrs
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3D Surface Plot of optimum conditions
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3D Surface Plot of optimum conditions
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Partial conclusion
Burr size can be reduced significantly by selecting appropriate
cutting parameters and cutting tools.
Depth of cut, feed per tooth and tool (insert nose radius and
coating) were found as the dominant process parameters on
most of the burrs.
For the most of the burrs studied, the dominant process
parameters on burr height have the opposite effect on burr
thickness.
Dislike few reported works in literature, burr size in slot milling

have no linear relationship to others.
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Prof D. Dornfeld in 2009 has pointed out the most

important research Problematic on burr
3. Burr size detection and estimation

4. Burr removal (Deburring)
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Design & Process integration
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Burr minimization design
59
Burr minimization in macro-planing
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Burr minimization in micro-planing
61
Exit Order Sequence (EOS)

Orientation of insert in
tool holder
Orientation of material being

deformed which constructs
the burr
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EOS Fundamentals
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EOS : Tool & workpiece interaction
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EOS mechanism
Orientation of the material
being pushed out or
broken (depending on
ductility of the material)
Process parameters
Insert geometry
Feed direction
Workpiece edge orientation
The exit order of the cutting tool has important effects on burr formation and
influences burr position and burr dimensions
Source:(Hashimura et al., ASME Manufacturing Journal , 1999)
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EOS vs Burr Size

6 different EOS modes
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EOS vs Burr Size

Depending upon cutting edge orientation, exit burrs form preferentially on the:
machined surface or the transition surface
Rigid workpiece
Sharp cutting edges and negligible nose radius
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EOS as a Process Planning Tool

EOS helps
- Choose a suitable tool insert geometry (axial, radial rake
angles, lead angle)
- Select suitable cutting parameters (feed, speed, DoC etc)

- Select suitable tool radius
- Calculate optimum offset from w/p edge in case of a
shoulder or other machining constraints
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Tool Path Planning for Burr

Minimization
Planar milling operation
tool diameter D, workpiece characteristic size M
69
Burr Minimization Tool Path Planning

Minimize burr formation by changing
tool path (tool engagement)
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Burr minimization tool path
zigzag tool path for clean up
71
Machined with burr minimization

tool path
Machined with regular tool path
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Burr prediction models

Analytical models
Certain levels of assumption is required
Requires the experimental observation of burr formation process [Toropov et al, 2005]
Consistent results can not be always obtained
Simulation models : Results are dependent to [Toropov , 2000]:

Exactness of input boundary conditions (usually simplified)
Software applied (ABAQUS, DEFORM, LS-DYNA, etc)
Additional experimental data (e.g. Flow stress coefficients)
Empirical models
Applicable only for a narrow range of process parameters
Varies based on a change in tool and material
Costly and time consuming
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FEM- simulation of burr formation
Source: (Sartkulvanich, Ph.D Thesis, Ohio state university, 2007)
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Source: (Deng et al., Int. J. of Advanced Manufacturing Technology, 2009)
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Burr formation process in

simple orthogonal cutting
Source: (Deng et al., Int. J. of Advanced Manufacturing Technology, 2009)
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Orthogonal cutting with positive rake angle
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Orthogonal cutting with large chip load
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Orthogonal cutting with negative rake angle
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Mostly use Johnson & Cook stress flow rule
Rarely 3D simulations models are reported for milling
The principle of Hydrostatic bowl on burr formation is still unclear.
Source: (Leopold and Wohlgemuth ,Springer, 2010)

Sartkulvanich,
Niknam, Seyed Ali June
3rd 20142007
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FEM- simulation of drilling burr formation
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FE Mesh
84
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Meshed Drill
Model
Meshed in Abaqus
Meshed in DEFORM
85
Drilling Simulation In DEFORM
Drilling Simulation in Abaqus
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Case study 2
Modeling of Burr Thickness in
Milling of Ductile Materials
By
Seyed Ali Niknam and Victor Songmene
Published in
Int. J. of Advanced Manufacturing Technology in 2013
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2014-05-30
Objective:
To develop the predictive model of exit up milling side burr (B1)
thickness as a function of cutting parameters.
B1 thickness is the longest and thickest milling bur.
It could be controlled by process parameters
Niknam and Songmene, Int. J. of Advanced Manufacturing Technology, 2013
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The assumptions used:

1.
Burr formation in the exit zone is

modeled as an orthogonal process.
2.
The model is based on the burr

formation geometry.
3.
The transition from chip formation to
burr formation occurs at the transition

point.
4.
The work done for chip formation is

equal to that done for burr formation.
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90
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Analytical Modeling
1
k0
2
2 cos 0 4 e tan 0
Ft a p Bt
tan 0
Where:
Symbol
Units
Description
Bt
(mm or m)
Burr thickness
ft
0
ap
e
k0
Ft
mm/z
(deg)
mm
(N/mm2)
(N/mm2)
N
Material properties (e & k0)
Feed per tooth

Initial negative shear angle
Axial depth of cut
Yield strength
Yield shear strength
Tangential force
Bt
f (Cutting parameters)
f (Cutting tool)
According to (Lauderbaugh, 2009), yield strength is the only statistically significant

material properties on exit burr formation amongst young modulus, thermal diffusivity,
and ultimate strength.
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Analytical Modeling
1
k0
2
2 cos 0 4 e tan 0
Ft a p Bt
tan 0
According to Von misses criteria:k0
3
The 0 = 20 under various cutting conditions and material studied [Ko and Dornfeld, 1991].
12
1
cos 2 0 + tan 0 )
(
12
4
Ft = - e a p Bt
tan 0
(
A=
12
1
cos 2 0 + tan 0 )
12
4
tan 0
Bt = -
Ft
eap A
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Experimental verification
Level
A: Depth of cut (mm)
B: Feed per tooth (mm/z)
0.01
0.055
0.1
C: Cutting speed (m/min)
300
750
1200
Lubrication condition: Dry ; Tool diameter (D : 19.05 mm)
18 tests were conducted in total for verifications

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AA 2024-T351
Correlation rate
97.22%
AA 6061-T6
Correlation rate
98%
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Computational Modeling
Bt = -
Ft
eap A
The only unknown parameter in model is Ft

The Ft can be computationally measured
1. Mechanistic force model [Altintas , 2000]

Ft ( ) K tc ah( ) K te a p
Fr ( ) K rc ah( ) K re a p
Fa ( ) K ac ah( ) K ae a p
dFt = Ktc h j ( j (a p )) + Kte d (a p )
dFr = K rc h j ( j (a p )) + K re d (a p )
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Computational Modeling
The effect of cutting speed on milling and drilling burrs size is statistically
insignificant (Lauderbaugh, 2009; Mian et al, 2011.
The effect of cutting speed on resultant force can be considered negligible

96
96
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Cutting force modeling approaches

2. Specific cutting force coefficient
Kc = K s (
ex
0.2 0.29
)
hm
hm =
ft sin (d )
st
ex - st
K c h j ( j (a p )) d (a p )
dBt.j ( j (a p )) =
e A ap
= ft
cos ex - cos ex
ex - st
Ft ( ) K C ah( )
Material properties (e , k0 and Kc)
Bt
f (ac , ft )
f (Tool geometry)
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97
Computational
Modeling
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Experimental verification
Level
0.01
0.055
0.1
A: Depth of cut (mm)

B: Feed per tooth (mm/z)
Lubrication condition: Dry ; Tool diameter (D : 19.05 mm)
6 verification tests were conducted for each material

99
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AA 6061-T6
AA 2024-T351
Correlation rate
99%
Correlation rate
97.33%
100
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Partial conclusion
Material properties (e , k0 and Kc)
The burr formation in exit zone
Bt
f (ac , ft )
f (Tool geometry)
was modeled.
B1 thickness was analytically and computationally modeled.
The models do not require the experimental measurements of shear

angle (), friction angle () and tool chip contact length (L).
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6. Burr measurement and detection

methods
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Burr detection and measurement methods

Burr detection and measurment
methods
Out-process
With contact
In-process
Contacless
1. Styullus method
2. Metallographical
methods
Optical
1. Optiocal microscope
2. Broscope/endscope
3. Scanning electron
microscope (SEM)
1. Light slit method

2. Laser traiangulation
3. Fring pattern projection
4. Autofocus methods
5. Confocal microscopy
1. Process monitoring
2. Moment
3. Force
4. Sound emission
analysis
Electro-Mechancial
1. Eddy-current sensor
2. Inductive senor
3. Computer tomography
(Niknam and Songmene, Ph.D Thesis, ETS, 2013)
103
Burr detection and measurement

methods
Three main burr size measurement systems:
1. Mechanical systems
2. Electrical systems
3. Optical systems
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Inductive Measurement Technique
Source: Patent by Gratsensorik, Manfred Jagiella; 2002-05-16
105
Burr sensors
106
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Inductive sensor: 2nd Generation
107
Burr sensors
108
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Burr detection and measurement

methods
110
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7. Burr removal (deburring) and

edge finishing
Deburring Process
Deburring includes all operations which are used to
remove a produced burr from simple hand deburring
to high tech surface finishing by NC controlled robots.
As a result of years of research, vast numbers of
methods have been developed. Some typical
deburring methods are introduced here with some
research efforts.
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Deburring Technologies
Objectives of deburring
- Remove burr
- Finish edge or otherwise condition the edge
- Insure burr is firmly attached
- Reduce burr size
- Facilitate handling/assembly
- Protect workers from injury
Facilitating deburring
- Locate burrs
- Predict burr size, shape and variation
- Determine accessibility
- Assist in deburring process set up (tool path, etc.)
- Evaluate deburring approaches for burr condition
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Classification of deburring operations

1. Mechanical Deburring Operations
2. Thermal Deburring Operations
3. Electrical Deburring Operations

4. Chemical Deburring Operations
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Deburring Technologies
The most frequently used deburring processes :
No. Deburring process
No.
Deburring process
Manual deburring
Barrel deburring
Brush deburring
Centrifugal barrel finishing
Bonded abrasive deburring
Robotic deburring
Abrasive jet deburring
Electro chemical deburring
Mass finishing
10
Vibratory finishing
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Mechanical Deburring Operations
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Thermal Deburring Operations

Torch or flame melting
Thermal energy method
Plasma flame
Plasma-glow deflashing
Hot wire
Resistance heating
Laser deburring
Electronic discharge machining (EDM)
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Electrical Deburring Operations

Electrochemical barrel tumbling
Electrochemical moving electrode
Electrochemical vibratory finishing
Electrochemical mesh deburring
Electrochemical roll flow finishing
Electrochemical brush deburring
Electrochemical spindle finishing
Electrochemical deburring
Electrochemical recipro finishing
Electropolish deburring
Electrochemical orboresonant finishing
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Chemical Deburring Operations

Chemical barrel finishing
Chemical magnetic finishing
Chemical vibratory finishing
Ultrasonic (chemical)
Chemical roll flow finishing
Chemical fluidized bed
Chemical spindle finishing
Chlorine gas deburring
Chemical centrifugal finishing
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Manual deburring
High flexibility than other methods;
Does not take much time for small burr;
Cheaper for small burrs;
(Niknam, Ph.D Thesis, ETS, 2013)
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Manual deburring
Disadvantages:
It generates a lot of surface scratches;
Deburring time is high for large burr;
It is difficult to attach the pieces (miniature pieces for example);
It is difficult to define the manual deburring standards;
There is a lack of manual deburring study;

Does not show a great motivation for industrial workers;
It is difficult to deburr some complex parts;
The deburring result is sometimes inconsistent;
Deburred edges are not uniform
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Burrs around Hole on Plane
Micro burr
Drilling burr
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Magnetic abrasive deburring
123
Experimental Deburring of Micro Burrs
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Deburring by Permanent Inductor
125
Brush Deburring
Deburring and Finishing with Brushes
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Brush Deburring
Benefits of NAF Brushes:
Deburr and finish in one step
Highly compliant on complex part geometry
Ideal for automated deburring in CNC centers
Do not alter part dimensions
Operating Information:
Flexible file filaments provide deburring action
through abrasion
Surface speeds are slow, generally below 3,500 SFPM
Penetration of the brush face is required
127
Brush Deburring
128
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Brush Deburring
129
Brush Deburring
130
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Brush Deburring
131
Brush Deburring
132
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Robotic deburring
Fast
Cheaper than CNC deburring
High consistency and repeatability
Can work in noisy and dirty conditions
require minimal intervention human
Can remove most of the type of burrs
Can be worked in automation
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Bonded-abrasive Deburring
Advantages
Low price;
Large variety of choices;
some varieties may improve the surface condition;
Adaptable to manual or automatic equipment;
Disadvantages
Sometimes affects the surface quality;
Effects on residual stresses;
Dust emission;
Changes the part dimensions;
Sometimes generate new burrs;
Changes the color of the part;
Lack of access to certain sides of part;
Low life;
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2014-05-30
Thank you
68

SYS 849 5 Lecture Burr Deburring and Edge Finishing

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2014-05-30

Surface Treatment, Finishing and Integrity:

cole de technologie suprieure (ETS)

4. Burr size minimization/optimization

7. Burr removal (deburring) and edge finishing

Definition of burrs according to ISO 13175

b) Large burr formation

Exit burrs observed when Drilling Al 6061-T6

b) Limited & non visible burr

Slot milling burrs

Niknam, Seyed Ali June 3rd 2014

A Short History of the Burr

Niknam, Seyed Ali June 3rd 2014

Burr Formation Studies

Niknam, Seyed Ali June 3rd 2014

Why are we interested to burrs ?

Source:(Aurich et al, CIRP Annals, 2009)

Niknam, Seyed Ali June 3rd 2014

Why are we interested to burrs ?

Source:(Aurich et al, CIRP Annals, 2009)

Niknam, Seyed Ali June 3rd 2014

Why are we interested to burrs ?

Category of expenses due to presence of burr

Source: (Aurich et al, CIRP Annals, 2009)

Niknam, Seyed Ali June 3rd 2014

Why are we interested to burrs ?

Niknam, Seyed Ali June 3rd 2014

2. Burr formation mechanism, shapes

Burr formation mechanism

Burr/breakout formation model:

Niknam, Seyed Ali June 3rd 2014

Burr formation mechanism

Source:(Hashimura, et al., ASME Manufacturing journal , 1999)

Niknam, Seyed Ali June 3rd 2014

Burr formation process

Source:(Hashimura, et al., ASME Manufacturing journal , 1999)

Niknam, Seyed Ali June 3rd 2014

Burr Formation Sequence in Al2024-O

Source: Laboratory for Manufacturing and Sustainability, UC-Berekley

Niknam, Seyed Ali June 3rd 2014

Edge Quality Standard

(Gillespie, Journal of Manufacturing Engineering, 1996)

Source: (Aurich et al, CIRP Annals, 2009)

Niknam, Seyed Ali June 3rd 2014

Measurement values of burr

Source: (Schfer, 1975)

Niknam, Seyed Ali June 3rd 2014

Various Types of Burrs in Machining

Source:(Aurich et al, CIRP Annals, 2009)

Niknam, Seyed Ali June 3rd 2014

Advanced Cutting Mechanics: Milling

Niknam, Seyed Ali June 3rd 2014

Advanced Cutting Mechanics: Milling

Niknam, Seyed Ali June 3rd 2014

Types of Burrs in Milling

Face milling burrs

Slot milling burrs

Source: (Lee, Ph.D thesis, UC-Berekley, 2004)

Niknam, Seyed Ali June 3rd 2014

Milling burr classification

Source: (Nakayama, Arai, CIRP Annals, 1987)

Niknam, Seyed Ali June 3rd 2014

Milling burr classification-Location