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Drilling Burr Minimization by Changing Drill Geometry.

Emilia Franczyk1, Łukasz Ślusarczyk1, Wojciech Zębala1

  • 1Production Engineering Institute, Mechanical Faculty, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland.

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Summary

This study optimized drill bit geometry to reduce burrs and drilling caps when machining titanium alloys. A modified drill bit geometry significantly decreased cutting forces and burr height, eliminating drilling caps.

Keywords:
burrscutting forcesdeburringdrillingtitanium alloy

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Mechanical Engineering

Background:

  • Drilling difficult-to-cut materials like titanium alloys (Ti-6Al-4V) often results in burrs and drilling caps.
  • These defects can compromise part quality and require additional post-processing steps.

Purpose of the Study:

  • To develop and validate a modified drill bit geometry to mitigate burr and drilling cap formation.
  • To determine the optimal chamfer dimensions for improved drilling performance in Ti-6Al-4V.

Main Methods:

  • Utilized Taguchi and ANOVA methods for experimental design and analysis.
  • Modified the margin of a FANAR drill bit with a chamfer of specific length and angle.
  • Compared cutting forces and burr heights using original and modified drill bits at various feed rates.

Main Results:

  • Identified an optimal chamfer geometry: 2 mm length and 10° angle.
  • Achieved a significant reduction in axial cutting force (22-23%) and burr height (10-22%).
  • Completely eliminated drilling cap formation with the modified drill bit.

Conclusions:

  • The optimized chamfer geometry on the drill bit margin effectively reduces burrs and eliminates drilling caps in Ti-6Al-4V.
  • A positive correlation exists between cutting force and burr size, highlighting the importance of force reduction.
  • The findings offer a practical solution for improving the efficiency and quality of drilling titanium alloys.