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A new burr formation model for drilling with tool wear

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Abstract

This paper presents a new burr formation model for predicting drilling burr sizes in consideration of tool wear. A new force model is established by combining the drilling thrust force with the ploughing force caused by tool wear. The traditional drilling burr formation model is modified by using the new force model to determine burr heights and thicknesses in terms of tool wear percentage. A series of drilling experiments are carried out on two commonly used aerospace aluminiums to validate and calibrate the model. A close agreement between simulation and experiment is achieved showing that burr height and thickness increase with the increase in tool wear, and at 50% of tool wear, the maximum burr height could triple and the maximum burr thickness could double.

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The data generated and analysed during this study are included in this paper.

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  • 28 April 2021

    Springer Nature’s version of this paper was updated to include e-mail address of the first author.

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Funding

This research is supported by the Natural Sciences and Engineering Research Council of Canada and the Zhejiang Provincial Natural Science Foundation of China (Grant No. LGG18E050018).

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Authors and Affiliations

  1. Department of Aerospace Engineering, Ryerson University, Toronto, ON, M5B 2 K3, Canada

    Anna M. Mandra & Fengfeng (Jeff) Xi

  2. Qianjiang College, Hangzhou Normal University, Hangzhou, 310036, Zhejiang, China

    Jiefeng Jiang

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  1. Anna M. Mandra
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  2. Jiefeng Jiang
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  3. Fengfeng (Jeff) Xi
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Contributions

1st author: PhD work; 2nd author: model improvement; 3rd author: PhD supervisor.

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Correspondence to Jiefeng Jiang.

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Mandra, A.M., Jiang, J. & Xi, F.(. A new burr formation model for drilling with tool wear. Int J Adv Manuf Technol 116, 1437–1450 (2021). https://doi.org/10.1007/s00170-021-07031-4

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  • DOI: https://doi.org/10.1007/s00170-021-07031-4

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