Skip to main content
SpringerLink
Log in

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

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Schafer F (1975) Product design influences on deburring. Society of manufacturing engineers technical paper MR, USA: 75-483

  2. Gillespie LK (1976) Burrs produced by end-milling. Bendix report BDX-613-1503, Bendix Corporation, Kansas City, Division in Kansas City, USA

  3. Pekelharing AJ (1984) The exit failure of cemented carbide face milling cutters: part 1—fundamentals and phenomena. Ann CIRP 33(1):47–50

    Article  Google Scholar 

  4. Ko SL, Dornfeld DA (1991) A study on burr formation mechanism. Trans ASME J Eng Mater Technol 113(1):75–87

    Article  Google Scholar 

  5. Gillespie LK (2006) Machinist can reduce or prevent burrs in the metal cutting process. Cut Tool Eng Mag 58(12):1–2

    Google Scholar 

  6. Dornfeld D, Min S (2009) A review of burr formation in machining. In: Proceedings of the CIRP international conference on Burrs, Kaiserslautern, Germany, pp 3–12

  7. Olvera O, Barrow G (1996) An experimental study of burr formation in square shoulder face milling. Int J Mach Tools Manuf 36(9):1005–1020

    Article  Google Scholar 

  8. Park I (1996) Modeling of Burr formation process in metal cutting. Dissertation, Department of Mechanical Engineering, University of California at Berkeley, USA

  9. Hashimura M, Chang YP, Dornfeld D (1999) Analysis of burr formation mechanism in orthogonal cutting. Trans ASME J Manuf Sci Eng 121(1):1–7

    Article  Google Scholar 

  10. Hashimura M, Hassamontr J, Dornfeld DA (1999) Effect of in-plane exit angle and rake angles on burr height and thickness in face milling operation. Trans ASME J Manuf Sci Eng 121(1):13–19

    Article  Google Scholar 

  11. Chu H (2000) Integrated edge precision machining. Dissertation, Department of Mechanical Engineering, University of California at Berkeley

  12. Rangarajan A, Chu CH, Dornfeld DA (2000) Avoiding tool exit in planar milling by adjusting width of cut. Trans ASME J Manuf Sci Eng 11:1017–1025

    Google Scholar 

  13. Lin TR (2000) Experimental study of burr formation and tool chipping in the face milling of stainless steel. J Mater Process Technol 108:12–20

    Article  Google Scholar 

  14. Avila MC, Dornfeld DA (2004) On the face milling burr formation mechanism and minimization strategies at high tool engagement. In: Proceedings of the international conference on deburring and edge finishing, University of California at Berkeley, USA, pp 191–200

  15. Shefelbine W, Dornfeld D (2004) The effect of dry machining on burr size. Consortium on deburring and edge finishing. Laboratory for Manufacturing and Sustainability, University of California, Berkeley

    Google Scholar 

  16. Lee K, Dornfeld DA (2005) Micro-burr formation and minimization through process control. J Precis Eng 29:246–252

    Article  Google Scholar 

  17. Chern GL (2006) Experimental observation and analysis of burr formation mechanisms in face milling of aluminum alloys. Int J Mach Tools Manuf 46:1517–1525

    Article  Google Scholar 

  18. Tripathi S, Dornfeld DA (2006) Review of geometric solutions for milling burr prediction and minimization. Proc Inst Mech Eng Part B J Eng Manuf 220(4):459–466

    Article  Google Scholar 

  19. da Silva LC, Anderson C, de Melo A, Macado AR, da Silva MB, Junior AMS (2006) Application of factorial design for studying the burr behaviour during face milling of motor engine block. J Mater Process Technol 179(1/3):154–160

    Article  Google Scholar 

  20. Kim YJ, Ko SL, Kim JH, Kim BK (2006) Development of intelligent system to minimize burr formation in face milling. Int J Adv Manuf Technol 29:879–884

    Article  Google Scholar 

  21. Lee SH, Dornfeld DA (2007) Prediction of burr formation during face milling using an artificial neural network with optimized cutting conditions. Proc Inst Mech Eng Part B J Eng Manuf 221(12):1705–1714

    Article  Google Scholar 

  22. Saha PP, Das D, Das S (2007) Effect of edge beveling on burr formation in face milling. In: Proceedings of the 35th international MATADOR conference, Taipai, Taiwan, pp 199–202

  23. Heisel U, Schaal AM, Wolf AG (2009) Burr formation in milling. Prod Eng Res Dev 3:23–30

    Article  Google Scholar 

  24. Schueler GM, Engmann J, Marx T, Haberland R, Aurich JC (2009) Burr formation and surface characteristics in micro-end milling of titanium alloys. In: Proceedings of the CIRP international conference on Burrs, Kaiserslautern, Germany, pp 129–138

  25. Silva JD, Saramago SFP, Machado A (2009) Optimization of the cutting conditions (vc, fz and doc) for burr minimization in face milling of mould steel. J Braz Soc Mech Sci Eng 31(2):151–160

    Article  Google Scholar 

  26. Saha PP, Das S (2011) An investigation on the effect of machining parameters and exit edge beveling on burr formation in milling. J Mechatron Intell Manuf 2(1/2):73–84

    Google Scholar 

  27. Saha PP, Das S (2011) Burr minimization in face milling: an edge beveling approach. Proc Inst Mech Eng Part B J Eng Manuf 225(9):1528–1534

    Article  Google Scholar 

  28. Das A, Mondal P, Samanta S, Das S, Mahata S (2011) Burr minimization in milling: through proper selection of in-plane exit angle. J Assoc Eng India 81:38–47

    Google Scholar 

  29. Saha PP, Das A, Das S (2013) On reduction of formation of burr in face milling of 45C8 steels. Mater Manuf Process 28(5):550–556

    Article  Google Scholar 

  30. Park IW, Dornfeld DA (2000) A study of burr formation processes using the finite element method: part II—the influences of exit angle, rake angle, and backup material on burr formation processes. Trans ASME J Eng Mater Technol 122:229–237

    Article  Google Scholar 

  31. Leopold J, Neugebauer R, Löffler M, Schwenck M, Hänle P (2006) Influence of coating-substrate systems on chip and burr formation in precision manufacturing. Proc Inst Mech Eng Part B J Eng Manuf 220(4):499–506

    Article  Google Scholar 

  32. Aurich JC, Dornfeld D, Arrazola PJ, Franke V, Leitz L, Min S (2009) Burrs: analysis, control and removal. CIRP Ann Manuf Technol 58:519–542

    Article  Google Scholar 

  33. Saha PP, Das A, Das S (2011) Burr minimization in shaping of En25 steels: using experimental and stress analysis techniques. Int J Manuf Technol Indust Eng 1(2):61–65

    Google Scholar 

  34. Sharan RV, Onwubolu GC (2011) Measurement of end-milling burr using image processing techniques. Proc Inst Mech Eng Part B J Eng Manuf 225(3):448–452

    Google Scholar 

  35. Klocke F, Eisenblatter G (1997) Dry cutting. Ann CIRP 46(2):519–526

    Article  Google Scholar 

  36. Montgomery DC (2007) Design and analysis of experiments. Wiley, New Delhi

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Kalyani Government Engineering College, Kalyani, West Bengal, India

    Partha Pratim Saha & Santanu Das

Authors
  1. Partha Pratim Saha
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Santanu Das
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Santanu Das.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Saha, P.P., Das, S. Minimization of exit burr in face milling of medium carbon steel by exit edge beveling. Prod. Eng. Res. Devel. 8, 469–476 (2014). https://doi.org/10.1007/s11740-014-0550-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-014-0550-2

Keywords

Search

Navigation