An analytical model for exit burrs in drilling of aluminum materials

Exit burr formation in drilling of aluminum materials is a common problem in aircraft assembly operations. Burrs formed at the exit surface of the workpiece need to be removed, and the deburring is a non-value but time and costs waste operation, particularly in automatic drilling and riveting assembly. This paper presents an analytical model of the exit burr formation to predict the burr height and thickness, and drilling experiments was developed to verify the availability of the proposed model. The impacts of process parameters, such as cutting force, spindle rotational speed, feed rate, and temperature effect were taken into consideration. Drill geometrical factors such as point angle, helix angle, chisel edge, and web thickness were also used to improve the practicability of the model. The differences between calculated burr size and experimental result were discussed, and specific conclusions were presented.

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