Deburring Process Research Articles

A study on the analysis method of shape quality and the micro burr removal on a micro pyramid pattern using the micro MR fluid jet polishing system

Recently, micro square pyramid patterns which can be obtained by a light diffusion effect have been widely studied and examined. However, micro pyramid patterns are difficult to fabricate, because of a deburring problem. Therefore, a micro machining technology for the fabrication of micro pyramid patterns has emerged as an essential element. Burr can almost be generated on the edge of the micro pattern when the micro square pyramid pattern is manufactured by a mechanical cutting process. The micro pyramid pattern shape is difficult to maintain as an original form when the burrs are removed. So various methods have been used in an attempt to remove the burrs. A micro magnetorheological (MR) fluid jet polishing process is one of various methods to remove burrs. The process can control shear force for material removing it by a controlled viscosity of the MR fluid due to magnetic-field adjusting. In this paper, magnetic analysis and the deburring process were carried out to fabricate a micro square pyramid pattern on brass (non-magnetic material) and nickel (ferromagnetic material) using a micro MR fluid jet polishing system. Finally, the deburring characteristics and the shape analysis of micro pyramid patterns were investigated by using a micro MR fluid jet polishing system.

Robust 3D Object Model Reconstruction and Matching for Complex Automated Deburring Operations

The deburring processes of parts with complex geometries usually present many challenges to be automated. This paper outlines the machine vision techniques involved in the design and set up of an automated adaptive cognitive robotic system for laser deburring of metal casting complex 3D high quality parts. To carry out deburring process operations of the parts autonomously, 3D machine vision techniques have been used for different purposes, explained in this paper. These machine vision algorithms used along with industrial robots and a high tech laser head, make a fully automated deburring process possible. This setup could potentially be applied to medium sized parts of different light casting alloys (Mg, AlZn, etc.).

Detection of Workpiece Shape Deviations for Tool Path Adaptation in Robotic Deburring Systems

Robotic systems have the potential to automate deburring processes along edges of arbitrarily shaped workpieces. The desired robot movement can be realized by proper trajectory planning using the computer-aided design (CAD) model of the manufactured workpiece. A fundamental problem is that geometric shape deviations between the nominal CAD model and the manufactured parts might be beyond acceptable limits for correct execution of the deburring process. This paper proposes a novel, easy to implement and practical approach to detect shape deviations of workpieces for automatic adaptation of robotic deburring processes. The approach only uses dimensional tolerance specifications of the manufactured part provided by the product design to derive possible variations of the workpiece geometry model. A matching process is performed between point clouds for each of the considered variants and a measured point cloud from the manufactured workpiece using an Iterative Closest Point (ICP) approach. Resulting point distances are used for evaluation of shape similarity between the compared point clouds. Finally, the most similar geometry model is identified for subsequent trajectory planning and workpiece localization. Experimental validation is performed by an industrial robot equipped with a stereo camera for shape sensing and a milling tool for subsequent execution of a deburring process. The results demonstrate the effectiveness and practicality of the proposed approach in industrial applications and an increased deburring quality.

Time Optimal Path Planning for Industrial Robots Using STL Data Files

This paper presents an approach based on the A*-Algorithm to generate time optimal tool paths for a robot based deburring process of internal contours. Besides the optimization of the deburring process by using special deburring tools with proper parameters the robots trajectory between the individual points has to be optimized to minimize the deburring process. The simulation environment OpenRAVE with a Matlab interface is used to find the shortest path by solving the traveling salesman problem of a graph automatically generated using the workpiece in the Surface Tessellation Language (STL) data file.

Localized Electrochemical Deburring of Cross Hole Using Gelatinous Electrolyte

Burrs are formed in mechanical processes such as cutting and blanking, and can have a number of negative effects, such as reducing product life. Burr removal generally depends on manual treatment methods due to the various shapes and properties of burrs. Deburring is therefore considered a significant issue in terms of achieving efficient production and automation. Electrochemical machining (ECM) is commonly used in the deburring of internal cross holes because of its high efficiency and lack of surface residual stresses. However, in the electrochemical deburring process, stray corrosion may cause loss of machining precision and surface quality. We herein propose a localized electrochemical deburring process using a gelatinous electrolyte to solve the problem of stray corrosion. As the gelatinous electrolyte is in contact with the burr surface without macroscopic liquid flow, electrochemical corrosion is confined to the narrow bounds of the burr. Our results indicate that the proposed process can maintain the original machined precision and surface quality while preventing stray corrosion, which is not possible using traditional ECM.

Hybrid deburring process assisted by a large pulsed electron beam (LPEB) for laser-fabricated patterned metal masks

The quality of pixels on displays and semiconductors is directly related to the surface quality of the patterned metal mask used. Burrs generated on the patterned metal mask can degrade the quality of pixels on microelectronic devices during the deposition process. In this study, experimental observations of abrasive deburring along with large pulsed electron beam (LPEB) irradiation were performed to evaluate the deburring effects on patterned metal masks. Numerical modeling of LPEB irradiation approximately predicted melting depths and the experimental studies revealed limitations in the size of burrs removed by LPEB irradiation. Thus a LPEB-assisted hybrid deburring process was developed to eliminate burrs of metal masks regardless of their size. The size of burrs remaining after the LPEB-assisted hybrid deburring process was reduced to approximately 7.2μm which was much less than the results of abrasive deburring alone (38.01μm). The burr size distribution was reduced by 85% and surface roughness (Ra) was decreased from 640nm to 121nm, indicating a uniform surface texture.

Analysis of Productivity for Manufacturing Processe Improvement of an Automobile Bearing Flange by Simulation Experiments

A bearing flange in the 6-speed automobile transmission is a substantial part that requires its precise dimension process with particularly smooth and clear surface. If there remains burr separated on the surface, it can cause the vital defection of an automobile. At present, the de-burring process has the problems such as inconsistent job performances and industrial diseases due to the experiences and fatigues when processed manually. For the resolution of those issues, the automation technology applying to robot instruments has been considered resulting in improved the productivity through the consistent work, prevention of industry diseases and flexible relocations of workers. Accordingly we have analyzed improving productivity of the burr removal process utilizing the robot by the witness simulation experiments. For this, we have initially analyzed it before and after de-process, regarding time of work a day, cycle time and number of workers etc., based on these we have designed and performed simulation experiments, where we have also analyzed the mean Work-in-Process fluctuation, mean lead time and error rate, furthermore having examined its process optimization afterward.

Measurement technology using Z axis adaptation for burrs formed on curved surfaces

Burr is an undesirable jutting out formed as a result of plastic deformation of a metal during cutting and shearing operations. Burr needs to be minimized by an effective deburring process to improve the efficiency of machining and the quality of product. There is also a growing need for a measurement method or suitable measurement device to inspect burrs, favorably at drilled holes, sizes ranging from micro to macro. In fact, without an appropriate measurement method, it has become more difficult to examine and measure burrs formed on a free surface. In this work, a burr measurement system is developed using a conoscopic holography sensor, which offers certain advantages over interferometry, triangulation, and dynamic focusing, for point-by-point distance mapping. The measurement system is further improved to measure burrs on curved and inclined exit surfaces, whose range exceeds the measurement range of sensors, by using a Z axis adaptation method.

Parametric analysis of magnetic abrasive deburring process

Machining burrs have been the most troublesome obstruction to high productivity and automation of manufacturing processes. A study of new cost-effective deburring processes has always been an area of keen interest for production engineers. This paper investigates the effectiveness of magnetic abrasive deburring (MADe) method for deburring burrs formed by drilling operation on brass workpieces. An experimental investigation has been conducted using in-house fabricated set-up to identify the effectiveness of process parameters and hole-edge quality before and after deburring. On the basis of the results, in general, the percent reduction in burr height depends mainly on the abrasive mesh size, working gap, deburring time and rotational speed of magnet. The effect of deburring time is found to be the most significant parameter amongst all parameters. This study concludes that the significant burr reduction and the effective improvement in hole-edge quality can be obtained by MADe method.

Improving the Productivity of Sheet Metal Stamping Subassembly Area Using the Application of Lean Manufacturing Principles

Companies frequently find techniques and tools to enhance productivity and quality for success in the long-term in order to maximize competitive advantage. To date, lean manufacturing principle is one of the successful improvement concepts that have been applied to eliminate waste and non-value added activities that occur in many companies. This paper explores a real work case study of the manufacturing sheet metal stamping process to demonstrate how lean manufacturing can help improve work efficiency. This study was conducted within 10 months, started from July 2013 till April 2014. Lean and other improvement tools and techniques such as visual control, Poka-Yoke, and 5s were applied to help companies identify areas of opportunity for waste reduction and improve the efficiency of production processes. Studies of the company processes showed that the deburring and polishing processes tend to create the most non-value added activities and should be addressed as quickly as possible. The improvement results have shown a positive impact on the company productivity improvements. The significant results indicate that the processing time of a polishing stage, after applying lean manufacturing principle, was reduced from 6,582seconds to 2,468seconds or by 62.5%. Also non-value added activities were reduced from 1,086 activities to 261 activities, or by 66.53%. Furthermore, overtime cost was reduced by 1,764 Dollar per year.

Energy consumption of the brushing process for PCB manufacturing based on a friction model

Industries are now required to use ‘green’ manufacturing due to emerging environmental concerns. In this study, the de-burring process for printed circuit board manufacturing was analyzed, and its energy consumption was examined based on a friction model. For de-burring of drilled micro-vias, a mechanical brushing process is typically used due to its performance and cost-effectiveness. However, it is very complex to analyze the energy consumption of a brushing process because a brush simply sweeps the surface with rotating metal wires, unlike conventional cutting processes. To construct an energy consumption model of a brushing process, its energy consumption was examined empirically considering a friction model. The brush was assumed to be an elastic body, and velocity strengthening and weakening of the friction coefficients were predicted. Experiments were performed to match the data, and the energy consumption model was validated. The power consumption of the brushing process showed a concave shape with respect to the rotational speed, and the overall power could be reduced by up to 40% by controlling the process parameters. The process parameters for the minimum energy consumption could be derived using the model considering local constraints such as burr height.

Minimization of exit burr in face milling of medium carbon steel by exit edge beveling

Elimination, or reduction, of burrs formed during machining is drawing focus of manufacturers and researchers since long or suppressing a burr regarding its formation or removal of it through a suitable deburring process. Deburring is an extra process often required to undertake, and it involves additional time and cost. Presence of burr may cause several problems, such as difficulty in assembly, dimensional inaccuracy, injury to the operator, etc. Like other industries, avoidance of burr on milled component surfaces in railways is of concern. In the present investigation, formation of burr in face milling is tried to reduce by beveling the exit edge of blocks of medium carbon steel (45C8) which is widely used in railways for manufacture of different components. Cutting conditions are also varied to observe the effect on burr formation. It is observed that at an exit edge bevel angle of 15°, negligible burr is formed at most of the cutting conditions undertaken, and hence, recommended.

Offline Programming for Robotic Deburring Process of Aluminium Wheels

The paper presents application of Siemens RobotExpert software of industrial robot offline programming. The deburring process of aluminium wheel is described and developed. The robotic work-cell contains robot ABB IRB 1600id and two axes positioner ABB IRBP A 750 D 1000 H 700. The final robot tool path is checked using the collision viewer, the joint status monitor, the tool centre point speed viewer and tracker.

Wet blasting as a deburring process for aluminum

Light weight aluminum has shown high applicability in the automobile industry for high fuel efficiency. However, the manufacturing of aluminum is limited by the deburring process owing to the difficulty in employing wet blasting. In this paper, we present experimental and computational studies on the deburring process of wet blasting for aluminum. The process conditions are analyzed to achieve high deburring performance that minimizes the surface damage. Parameters of wet blasting with a significant influence on the deburring process are investigated and a promising deburring technique for aluminum is proposed.

Deburring of Cross Holes in Titanium Using Industrial Robots

In aircrafts, hydraulic systems control moveable parts. For example parts like the front strut or the landing flaps. These parts are usually made from aluminium or titanium. Due to an increasing number of functions these valves show an increasing number of cross holes. The production process causes burrs at the intersection of the holes. Until now these burrs cant be removed reliably by an automated process. Remaining burrs can influence dimensional tolerances and reduce the efficiency and technical lifetime of the component. In some applications cross holes are used for the lubricant and coolant supply. In this case burrs can lead to blockades of critical passages or cause turbulences in the fluid. This can lead to leakage or bursting of the valve. Hence an uncontrolled removal of the burr during operation must be avoided. The consequence of these basic conditions is a time consuming manual deburring process. An automated deburring process of cross holes with industrial robots is usually performed with flexible abrasive brushes. Alternatively processes like AFM (Abrasive Flow Machining), ECM (Electro Chemical Machining) or TEM (Thermal Energy Machining) are used. Those processes are very efficient but require specialized equipment and cleaning processes for the used chemicals and the remaining abrasive paste. So they are not suitable for the deburring of safety related parts. This paper presents an experimental based approach for the robot based deburring of cross holes using industrial robots. For the deburring of cross holes several special tools are available. This article gives a short overview over the specific advantages and disadvantages of these tools. As the investigations revealed the best results can be achieved using the so called Orbitool developed by JWDone. The Orbitool is a tungsten carbide cutter developed for the deburring of cross holes. A better control of the required dimension at the intersection compared to brushes and other deburring methods is possible. Furthermore the tool can be used on machine tools and industrial robots and is flexible to a huge variety of bore diameters. The tool mainly consists of a ball shaped carbide milling cutter with a protective disk which is made of polished steel and a shaft of tool steel. To remove the burr the tool is moved along the bore axis into the smallest of the intersecting holes until the tip of the tool is close to the intersection. Then the tool is moved in radial direction to the bore surface until the tool axis corresponds to the interpolation diameter. This causes a deflection of the tool. In this situation only the protective disk is in contact with the bore surface. While the tool rotates it is moved towards the intersection in a helical motion. When the tool tip has reached the intersection the cutting edges get in contact with intersection and the deburring process begins. After the tool has passed the whole intersection it stops its rotation and is moved to the bore hole centre and then moved out of the workpiece. This paper deals with the optimization of the deburring process. The result mainly depends on the parameters movement speed of the robot, slope of the helical movement and rotational speed of the tool. The experiments are planned using DOE (Design Of Experiment) methods. Initial values for the optimization of the movement speed were determined by grid encoder measurements. Robotic specific parameters like the number of interpolating points and the influence of the path smoothing caused by the controller were also investigated. For the analysis of the burr and the secondary burr an optical 3-D measurement system is used. The results show that with the presented approach the burrs can be reliably removed. Before the deburring process the average burr height is about 60 μm and can be reduced so that there is no secondary burr visible. The result is a chamfer between 150 μm and 85 μm that depends on the process parameters. It can be demonstrated that a chamfer that is smaller than 100 μm leads to a secondary burr. Anyway the cycle time can be reduced from about 3 minutes for manual deburring to 30 seconds using an industrial robot. Additional wear analysis show that about 200 bore holes can safely be deburred.

A Study on Deburring Process of Micro Channel Using Ep and MAP Hybrid Process

Magnetic abrasive polishing is one of the most promising finishing methods applicable to complex surfaces. Nevertheless this process has a low efficiency when applied to very hardened materials. For this reason, EP-MAP hybrid process was developed. EP-MAP process is expected to machine complex and hardened materials.In this study, deburring process using EP-MAP hybrid process was proposed. EP-MAP hybrid deburring process is applied to micro channel, and thereby it can obtain both deburring process and polishing process. To evaluate the performance criteria of the EP-MAP hybrid deburring process, EP-MAP hybrid deburring process on the micro channel was performed. Through investigating the effect of working parameters, namely magnetic flux density, electric potential, working gap and feed rate, error of height and surface roughness according to working parameter is analyzed using design of experiment method.

전해-자기 복합 가공을 이용한 마이크로 채널 디버링공정 최적화

Magnetic abrasive polishing is one of the most promising finishing methods applicable to complex surfaces. Nevertheless this process has a low efficiency when applied to very hardened materials. For this reason, EP-MAP hybrid process was developed. EP-MAP process is expected to machine complex and hardened materials. In this research, deburring process using EP-MAP hybrid process was proposed. EP-MAP deburring process is applied to micro channel, thereby it can obtain both deburring process and polishing process. EP-MAP deburring process on the micro channel was performed. Through design of experiment method, error of height in this process according to process parameter is analyzed. When the level 1 parameter A(magnetic flux density) and level 2 parameter B(electric potential), C(working gap) and level 3 parameter D(feed rate) are applied in the deburring process using EP-MAP hybrid process, it provides optimum result of EP-MAP hybrid deburring process.

전해-자기 복합 가공을 이용한 미세 그루브형상의 가공 특성에 관한 연구

Magnetic abrasive polishing is an advanced deburring process for nonmagnetic materials and micropattern products that have non-machinability characteristics. Despite these advantages, there are some problems with using MAP for deburring. MAP has introduced geometric errors into microgrooves because of an over-cutting force caused by uncontrolled magnetic abrasives in the MAP tool. Thus, in this study, to solve this problem, an EP (electrolyte polishing)-MAP hybrid polishing process was developed for deburring microgrooves in an STS316 material. In addition, an evaluation of EP-MAP for the deburring of microgrooves was carried out by profiling the burrs. The results of the experiment showed geometric errors after the deburring process using MAP. However, in the case of EP-MAP, no geometric error was observed after the process because of the lower material removal rate in EP-MAP.

Development of a Non-Contact Micro-Deburring Method Using Ultrasonic Cavitation Bubbles

The purpose of this study is to develop a non-contact deburring method and optimize its operation parameters. A deburring method using enhanced ultrasonic cavitation without abrasives is proposed and its work conditions were optimized. In additional, aging changes on the microhardness and surface roughness of specimens were studied experimentally in the process. The aging microhardness went through two stages. In the first stage, the work hardening characteristic of aluminum induced the increase in microhardness of specimen. After the microhardness reached an extreme, it went down. The surface roughness increased with treatment time. These time-dependent changes indicated that parts should be treated discontinuously during the ultrasonic deburring process to avoid being eroded by cavitation bubbles. Deburring experiments indicated that the burrs can be effectively removed by these enhanced cavitation bubbles.

Force Control with Vision Feedback for Robotic Deburring Processes

Force Control with Vision Feedback for Robotic Deburring Processes