Title: Burr formation and elimination in micromilling processes

Authors: Mark J. Jackson, Grant M. Robinson, Michael D. Whitfield, Waqar Ahmed

Addresses: Birck Nanotechnology Center, College of Technology, Purdue University, West Lafayette, IN 47907, USA. ' Birck Nanotechnology Center, College of Technology, Purdue University, West Lafayette, IN 47907, USA. ' Birck Nanotechnology Center, College of Technology, Purdue University, West Lafayette, IN 47907, USA. ' Nanotechnology Research Institute, University of Ulster, Newtownabbey, County Antrim BT37 0QB, UK

Abstract: Machining at any scale usually produces burrs on surfaces; burrs are unwanted and add cost to the part. In general machining parameters are optimised to prevent burr formation, the cutting tool is assumed to be worn and is changed when burrs appear. When burrs appear on the part they must be deburred. At the micro scale deburring has been shown to be impractical because excessive dimensional errors and high tensile residual stresses are induced into the part. This study examines three methods of preventing burr formation: using coated tools to prevent tool wear; selecting a workpiece with a low amount of dislocations to prevent plastic deformation; and using machinable vice jaws to manipulate the flow stress. All these methods succeeded in suppressing burr formation.

Keywords: burrs; micromachining; cutting tools; burr formation; burr elimination; coated tools; tool wear; workpiece selection; dislocations; plastic deformation; machinable vice jaws; flow stress; nanomanufacturing.

DOI: 10.1504/IJNM.2007.014565

International Journal of Nanomanufacturing, 2007 Vol.1 No.4, pp.458 - 467

Published online: 16 Jul 2007 *

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