Burrs - Analysis, Control and Removal: Proceedings of the CIRP International Conference on Burrs, 2nd-3rd April, 2009, University of Kaiserslautern, Germany

249 Pages·2010·13.74 MB·English

by  D. Dornfeld

Burrs – Analysis, Control and Removal
·
Jan C. Aurich David Dornfeld
Editors
Burrs – Analysis,
Control and Removal
Proceedings of the CIRP
International Conference on Burrs,
2nd–3rd April, 2009,
University of Kaiserslautern, Germany
123
Editors
Prof.JanC.Aurich
UniversityofKaiserslautern
InstituteforManufacturingTechnologyandProductionSystems-FBK
Gottlieb-Daimler-Straße
67663Kaiserslautern
Germany
[email protected]
Prof.DavidDornfeld
UniversityofCaliforniaatBerkeley
DepartmentofMechanicalEngineering
5100AEtcheverryHall
Berkeley,CA94720-1740
USA
[email protected]
ISBN978-3-642-00567-1 e-ISBN978-3-642-00568-8
DOI10.1007/978-3-642-00568-8
SpringerHeidelbergDordrechtLondonNewYork
LibraryofCongressControlNumber:2009926960
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Preface
The International Conference on Analysis, Control and Removal of Burrs, held at the
University of Kaiserslautern, Germany, marks the end of the three-year cycle of the CIRP
workinggrouponBurrs.Duringtheseyears,researchersaswellasexpertsfromindustryhave
contributed and gathered knowledge on research and industrial practice in the area of burrs,
edgeconditionsandpartcleanliness.ACIRProundrobinhasbeencarriedoutwithparticipants
inmanycountriesandthreecontinentstocompareavailablemethodsonburrmeasurement.
Thisconferencenowbringstogetherthemembersoftheworkinggroupaswellasexperts
fromindustryandacademiafromallovertheworldtodiscussthestateoftheartinresearch
aswellasindustrialapplicationsintheareaofburrsinonefocusedconferencewithaspecial
workshopcharacter.Theconferenceshallprovideaforumfortheintenseexchangeofconcepts
andmethods,thedisseminationoftechnologicalbreakthroughs,andfordiscussionsoffuture
directionsofresearchanddevelopment.
Theconferenceprogramcoversabroadspectrumoftopicsrangingfromstandardsforburr
description and classification and the mechanics of burr formation over modeling and sim-
ulation of the underlying mechanisms to burr control and deburring strategies. Our special
appreciation goes to the invited keynote speakers: Prof. Dornfeld from UC Berkeley, USA,
oneoftheleadingexpertsinthefield,willgiveanoverviewofthestateofresearchinanalysis,
controlandremovalofburrs.Prof.BiermannfromTUDortmund,Germany,willdrawonhis
scientificandindustrialexperiencetopresentburrreductionandcontrolstrategies.Mr.Berger
fromDaimler,Germany,andDr.MartinsenfromRTIM,Norway,willgiveaninsightintothe
industrialimportanceofburrissuesandpartcleanliness.
Our special gratitude goes to the International Program Committee and Local Organizing
Committee members for their wonderful efforts in reviewing papers, handling papers, and
preparingthetechnicalandsocialprogram.Withouttheireffortanddedicationtheconference
would not have been possible. We would also like to extend our sincere appreciation to the
paperauthorsfortheirexcellentcontributionstotheconference.Theauthorswhoarewilling
to share their most recent findings in basic research as well as in industrial application, both
in presentations and in many discussions in and around the technical sessions, represent the
dominant factor in the success of this conference. Finally, the organizations and companies
whocontributedtothefinancialsupportoftheconference,eveninfinanciallydifficulttimes,
deserve our great respect for their contribution. We would also like to thank the companies
whoopenedtheirfacilitiesfortheindustrialtour.Theyallowedgivingthisconferencethefinal
touchofstronginteractionbetweenresearchinstitutionsandindustry.
v
vi Preface
On behalf of the organizing committee, I wish all of you a successful conference, with
exciting technical sessions, fruitful discussions and a perfect get together of our research
community.
JanC.Aurich DavidDornfeld
Kaiserslautern,Germany Berkeley,CA,USA
Contents
Keynotes
AReviewofBurrFormationinMachining . . . . . . . . . . . . . . . . . . . . . . 3
D.DornfeldandS.Min
BurrMinimizationStrategiesinMachiningOperations . . . . . . . . . . . . . . . 13
D.BiermannandM.Heilmann
BurrFormationandAvoidanceforRobustCircularBladeSawingofThin
WalledExtrudedAluminumProfiles . . . . . . . . . . . . . . . . . . . . . . . . . . 21
K.MartinsenandG.Ringen
Mechanics,ModelingandSimulationofBurrFormation
BurrandCapFormationbyOrbitalDrillingofAluminum . . . . . . . . . . . . . 31
E.BrinksmeierandS.Fangmann
CuttingForceModelforAnalysisofBurrFormationinDrillingProcess . . . . . . 47
T.MatsumuraandJ.Leopold
BurrFormationinMicrostructuringProcesses . . . . . . . . . . . . . . . . . . . . 55
B.Denkena,L.deLeon,andJ.Kästner
AnalyticalModelingandExperimentalInvestigation
ofBurrFormationinGrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
H.Sudermann,I.G.ReichenbachandJ.C.Aurich
DevelopingaProcessModelforAbrasiveFlowMachining. . . . . . . . . . . . . . 73
E.Uhlmann,V.Mihotovic,H.Szulczynski,andM.Kretzschmar
ModelingandSimulationofBurrFormation:State-of-the-Art
andFutureTrends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
J.LeopoldandR.Wohlgemuth
BurrandChipFormationMechanisms
InterfacialBurrFormationinDrillingofStackedAerospaceMaterials . . . . . . 89
S.N.Melkote,T.R.Newton,C.Hellstern,J.B.Morehouse,andS.Turner
BurrFormationinDrillingIntersectingHoles . . . . . . . . . . . . . . . . . . . . 99
L.Leitz,V.Franke,andJ.C.Aurich
ChipBreakagePredictionbyaWeb-basedExpertSystem . . . . . . . . . . . . . . 107
F.Klocke,D.Lung,andC.Essig
vii
viii Contents
Parameterswith InfluenceonBurrFormation
SizeEffectsinDrillingBurrFormation . . . . . . . . . . . . . . . . . . . . . . . . 117
R.Neugebauer,G.Schmidt,andM.Dix
Burr Formation and Surface Characteristics in Micro-End Milling
ofTitaniumAlloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
G.M.Schueler,J.Engmann,T.Marx,R.Haberland,andJ.C.Aurich
InfluenceofMinimumQuantityLubricationonBurrFormationinMilling . . . . 139
U.Heisel,M.Schaal,andG.Wolf
BurrFormationandRemovalatProfileGrindingofRibletStructures . . . . . . . 147
B.Denkena,L.deLeon,andB.Wang
BurrMeasurement
BurrMeasurementSystemforDrilledHoleatInclinedExitSurface . . . . . . . . 157
H.P.HoangandS.L.Ko
BurrMeasurement:ARoundRobinTestComparingDifferentMethods . . . . . 167
V.Franke,L.Leitz,andJ.C.Aurich
DeburringProcesses–Fundamentals
DeburringwithCO SnowBlasting . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2
E.Uhlmann,M.Kretzschmar,F.Elbing,andV.Mihotovic
AStudyonDeburringInconel718UsingWaterJetTechnology . . . . . . . . . . . 189
F.Boud,J.Folkes,N.Tantra,S.Kannan,andI.W.Wright
IceBlasting–AnInnovativeConceptfortheProblem-OrientedDeburring
ofWorkpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
B.KarpuschewskiandM.Petzel
DeburringProcesses–Applications
Study of Internal Deburring of Capillary Tubes with Multiple
Laser-machinedSlits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
H.YamaguchiandJ.Kang
RoboticDeburringBasedonOn-lineBurrMeasurement . . . . . . . . . . . . . . 213
L.Liao,F.Xi,andS.Engin
DeburringMachineforRoundBillets–EquipmentforEfficientRemoval
ofBurrsfromBillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
M.Schnabl
RemovalandCleanability
FormulationoftheChipCleanabilityMechanicsfromFluidTransport . . . . . . 229
S.Garg,D.Dornfeld,andK.Berger
BurrMinimizationandRemovalbyMicroMillingStrategiesorMicro
PeeningProcesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
A.Kienzler,M.Deuchert,andV.Schulze
AssessmentofDeburringCostsinIndustrialCaseStudies . . . . . . . . . . . . . . 245
P.J.Arrazola
AuthorIndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
A Short View on CIRP
CIRPwasfoundedin1951withtheaimtoaddressscientifically,throughinternationalcooper-
ation,issuesrelatedtomodernproductionscienceandtechnology.TheInternationalAcademy
for Production Engineering takes its abbreviated name from the French acronym of College
International pour la Recherche en Productique (CIRP) and includes ca. 550 members from
41countries.Thenumberofmembersisintentionallykeptlimited,soastofacilitateinformal
scientificinformationexchangeandpersonalcontacts.
CIRPhassome170FellowsandHonoraryFellowswhoareinternationallyrecognizedsci-
entists elected to be CIRP members for life. Due to the limited number of CIRP Fellows,
theelectionofaFellowisalengthy,rigorousprocessensuringthehighestpossibleacademic
standards.
CIRP includes some 130 associate members, well known scientists, with high potential,
electedtypicallyforaperiodofthreeyearswiththepossibilityofrenewal.AnumberofAsso-
ciate members eventually become Fellows. Some Associated members may also belong to
fieldsrelatedtoManufacturing.
CIRP, although an academic organization, encourages the participation of industry in its
activities.Thereareca.140corporatememberswhofollowtheresearchworkoftheacademic
members of CIRP, and very often contribute to the information exchange within CIRP by
presentingtheirviewsonindustrialneedsandperspectives.
Invitedmembers,particularlyfromcountriesnotyetinvolvedinCIRP,arealsoincludedin
theCIRPcommunity.
In a recent development, there is work under way to establish a CIRP Network of young
scientistsactiveinmanufacturingresearch.
CIRPaimsingeneralat:
(cid:129) Promotingscientificresearch,relatedto
(cid:129) manufacturingprocesses,
(cid:129) productionequipmentandautomation,
(cid:129) manufacturingsystems,and
(cid:129) productdesignandmanufacturing.
(cid:129) PromotingcooperativeresearchamongthemembersoftheAcademyandcreatingopportu-
nitiesforinformalcontactsamongCIRPmembersatlarge.
(cid:129) Promotingtheindustrialapplicationofthefundamentalresearchworkandsimultaneously
receivingfeedbackfromindustry,relatedtoindustrialneedsandtheirevolution.
(cid:129) Organizing an annual General Assembly with keynote and paper sessions and meetings
of the Scientific and Technical Committees, publishing papers, reports, annals and other
technicalinformation,organizingandsponsoringinternationalconferences.
CIRPisorganizedalongthelinesofanumberofScientificTechnicalCommittees(STCs)
and Working Groups (WGs), covering many areas. CIRP organizes annually a General
Assembly and the so called January Meetings. In the General Assembly (GA), which lasts
ix
x AShortViewonCIRP
for a week, there is an intensive technical program with over 140 technical paper presenta-
tionsfromdifferentfieldsofmanufacturing,anumberofkeynotepapers,attheopeningofthe
conference,aswellastechnicalworkwithintheSTCs.Inparallel,thereisasocialprogram,
aimingatmakingthecultureoftheGeneralAssemblysiteknowntothemembersandalsoat
creatinganinformalenvironmentforinformationexchangeamongthemembers.TheJanuary
meetingsarealwaysorganizedinParis,andlastthreedays.MoreoverCIRPorganizes,through
itsmembership,anumberofconferences,notablytheManufacturingSystemsSeminaranda
number of other conferences with relevant topics. CIRP members also organize a variety of
conferences,underthesponsorshipofCIRP.
The main publications of CIRP are the CIRP Annals under ISI standards with two vol-
umes; Volume I, with refereed papers presented in the GA by Fellows, Associate, Corporate
and Invited members and Volume II with refereed keynote papers. There are also CIRP pro-
ceedings,includingroundtablediscussions,technicalreports,specialissues,reportsandinter-
nalcommunications,proceedingsofCIRPconferences,dictionariesofproductionengineering
etc.ANewsletterisalsopublishedtwiceayear.CurrentlytheCIRPAnnalsarepublishedby
Elsevier, while Springer Verlag publishes the Dictionaries of Production Engineering. There
areunderdevelopmentoneormorejournals,complementingtheworkpublishedintheCIRP
Annals.
TheCIRPorganizationincludesbesidesthePresident,whoiselectedannually,theCouncil
andanumberofothercommitteesensuringacontinuousimprovementoftheCIRPorganiza-
tionandreflectingthechangingneedsofmanufacturingscienceandtechnology.
CIRPhasitsheadquartersinParis,staffedbypermanentpersonnelandwelcomespotential
corporatemembersandinterestedpartiesinCIRPpublicationandactivitiesingeneral.
Forfurtherinformationpleasecontact:
CIRPSecretariat,9rueMayran,75009PARIS,France
Phone:++33145262180,Fax:++33145269215
e-mail:[email protected]
http://www.cirp.net/secretariat/secretariat.html