When drilling holes, burrs are created in particular on the exit surface. Existing deburring tools and methods enable the deburring of plane exit surfaces or slightly curved cross-drilled holes. However, these tools do not meet practical requirements for deburring in the machining industry where component geometries are often complex. This paper presents a numerical method, which enables deburring of complex-shaped drilling intersections with ball-end cutters. First, the particular intersection is analysed as it defines the maximum tool diameter of the ball-end cutter. Subsequently, a three-axis tool path for ball-end cutters is generated to correlate with the intersection geometry thus enabling constant chamfering and avoiding tool collisions. The model is verified by an experiment using the material AlSi7Mg and measuring secondary burr heights and chamfer widths. Subsequently, the functionality of the model for further geometry variants is investigated.
Deburring Ball-end cutter Tool path generation Freeform surface and complex intersection Modelling and algorithm Quality
This is a preview of subscription content, log in to check access.
The authors are responsible for the content of this publication. The authors are also grateful to the anonymous reviewers for their constructive criticism which served to improve this paper.
This research and development project is funded by the German Research Foundation (DFG AB 133/94-1).
Gillespie LK, Blotter PT (1976) The formation and properties of machining burrs, J Eng Ind Trans ASME Feb:66–74Google Scholar
Gillespie LK, Albright RK, Neal BJ (1976) Burrs produced by end milling, Bendix, Kansas City Division, BDX6131503Google Scholar
Dornfeld DA, Kim JS, Dechow H, Hewson J, Chen LJ (1999) Drilling burr formation in titanium alloy, Ti-6Al-4V. Ann CIRP 48(1):73–76CrossRefGoogle Scholar
Dornfeld DA (2004) Strategies for preventing and minimizing burr formation, CIRP HPC Conference, AachenGoogle Scholar
Min S, Kim J, Dornfeld DA (2001) Development of a drilling burr control chart for low alloy steel, AISI4118. J Mater Process Technol 113:4–9CrossRefGoogle Scholar
Aurich JC, Dornfeld DA, Arrazola PJ, Franke V, Leitz L, Min S (2009) Burrs–analysis, control and removal. CIRP Ann Manuf Technol 58(2):519–542CrossRefGoogle Scholar
Beier H-M, Nothnagel R (2015) Praxisbuch Entgrattechnik – Wegweiser zur Gratminimierung und Gratbeseitugung für Konstruktion und Fertigung, 2nd edn. Hanser, MünchenCrossRefGoogle Scholar
Aurich JC (2006) SpanSauber – Ergebnisbericht der Untersuchung zur Beherrschung der Sauberkeit von zerspanend hergestellten Bauteilen, Lehrstuhl für Fertigungstechnik und Betriebsorganisation. Technische Universität Kaiserslautern, KaiserslauternGoogle Scholar