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Sanjib Kundu ¹, Santanu Das ¹, Partha Pratim Saha ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, West Bengal 741235, IN

Abstract

Presence of burr after a manufacturing process is a potential problem. Prediction of burr size in machining plays an important role in process planning. The present work deals with the study and development of a burr height prediction model during machining aluminium alloy, using Response Surface Methodology (RSM). Drilling parameter such as cutting velocity, feed rate and drill diameter are considered in conducting experiments in a radial drilling machine to find out height of burr formed in aluminium alloy flats. By performing ANOVA, it is found that drill diameter is the most significant factor to influence formation of burr height. Combination of process parameters giving small burr height is found out within the experimental constraints. Three-dimensional surface and contour plots show the variation in burr height with different process parameters. A comparison of modeled and experimental results corresponding to a low burr height shows an error of less than 3%.

Keywords

Drilling, Burr Height, RSM, ANOVA, Size Effect.

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Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, Nadia-741 235, West Bengal, IN

Abstract

Production of high precision components needs constant attention to both the generation of machined surfaces without a burr and undertaking deburring operation. A machining process usually produces burr. In shaping, burr formation occurs when the cutting tool exits the workpiece. Absence of necessary back up support around an edge is the possible reason behind it. Several research works have been done on burr formation mechanism, its minimization, and deburring. A number of experiments is performed in this work on medium carbon steel (45C8) flats in dry condition to note the effects of burr formation on the workpiece with beveled exit edge. The experimental result shows that at 15o edge bevel, negligible burr formation is obtained. Analysis of variance is conducted on the experimental results to find out the relative influence of each process parameter on burr height observed. The regression analysis is also done with the experimental data and the regression equation gives fairly good estimate of experimental results.

Keywords

Machining, Shaping, Edge Beveling, Exit Edge, Burr.

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Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani 741 235, West Bengal, IN

Abstract

Foot formation in the workpiece during shaping operation is not favourable with early tool fracture, when a cutter exits the workpiece edge. Foot formation occurs due to gradual rotation of the positive shear plane to the negative shear plane about a pivot point. A number of tests in shaping operation is done in the present work on nickel chrome steel (En25) flats. Experiments are carried out in dry environment under different cutting velocities, rake angles and exit edge bevel angles to note the effect of foot formation. Experimental results are analyzed through ANOVA to find out the significance of the effect of cutting parameters and exit edge bevel angle to minimize the foot formation. It is observed foot formation that an exit edge bevel angle has the most significant effect. An exit edge bevel angle of 150 is recommended in orthogonal shaping operation when no foot formation is found.

Keywords

Shaping, Edge Beveling, Foot formation, Shear Plane, ANOVA.

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Partha Pratim Saha ¹, Dipankar Das ¹, Santanu Das ¹

Affiliations
1 Dept. of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741 235, IN

Abstract

Presence of burr at the edge of finished workpiece often leads to difficulty in assembly operation and injury to operator necessitating incorporation of additional processes of deburring. Exit burr formation by milling usually occurs when cutter moves out of the work piece. One method for minimizing this problem is to prevent the tool from exiting the workpiece while removing material. Burr formation can also be reduced considerably by edge beveling of the workpiece. In the present work, the influence of beveling the exit edge of the workpiece on the burr formation in milling has been experimentally investigated to find out the optimum condition to control the formation of burr.

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Partha Pratim Saha ¹

Affiliations
1 Kalyani Government Engineering College, Jig & Tool Design Office, Eastern Railway, Kanchrapara Workshop, IN

Abstract

The competitive pressures are throwing new challenges to the business world. In past, quality acted as a distinguishing characteristic between a company and its competitors. In today's world, however, quality has become mandatory. It is an assumed characteristic. The distinguishing features then become verifiable quality, continuous improvement, innovation, superior customer service, etc.

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Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani 741 235, West Bengal, IN

Abstract

At the exit edge of the wokpiece, burrs are usually found during shaping operation. Gradual rotation of the positive shear plane to the negative shear plane may be the reason behind it. This is due to absence of any support material at the exit end of cut. In the present work, a number of orthogonal shaping experiments is performed on aluminium alloy (4600-M) in dry environment under different cutting velocities, orthogonal rake angles and exit edge bevel angles to observe the occurrence of burr formation. Experimental results are analysed through ANOVA to find out the significance of the effect of cutting parameters and exit edge bevel angle to control the exit burr formation. It is noted that exit edge bevel angle has the most significant effect. An exit edge bevel angle of 15° is recommended in shaping operation when burr becomes negligible.

Keywords

Shaping, Edge Beveling, Exit Edge, Burr, Burr Minimization, ANOVA.

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Kapil Roy ¹, Partha Mukherjee ¹, Ujjwal Kumar Hansda ¹, Sourav Halder ¹, Suman Mandal ¹, Saikat Mandal ¹, Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Mechanical Engineering Department, Kalyani Govt. Engineering College, Kalyani-741235, IN

Abstract

Burr is a undesirable projected material adhered to an edge of a job. After drilling operation, exit burr which is usually produced beyond the rear surface of the workpiece, causes serious problem in the assembly of finished product and to maintain its quality. So, reduction of burr is essential. A number of experiments have been done in the present work under dry and wet environment to observe its effect on burr formation under different drilling conditions. In this work, an exit edge bevel of 31 degree or a back-up support is provided, and its influence on burr formed under different cutting velocities and feeds has been experimentally studied.

Keywords

Drilling, Machining, Burr, Exit-Edge Bevel, Back-Up Support, Dry Machining, Wet Condition.

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Atanu Das ¹, Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani - 741235, West Bengal, IN

Abstract

Burrs are formed in milling at the exit of the workpiece and it is three dimensional in nature. The exit burr height and thickness are varied with in-plane exit angle. It is also the prime factor of burr formation mechanism. This work presents a condition to obtain minimum burr formation at different exit edge bevel angles of the workpiece made of nickel chrome alloy steel with the varied in-plane exit angle of the cutter. In this experiment under dry environment, negligible burr is observed at 15° exit edge bevel angle when in-plane exit angle is 60°.

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Kapil Roy ¹, Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Mechanical Engineering Department, Kalyani Govt. Engineering College, Kalyani, West Bengal, IN

Abstract

In drilling, burr formation is mostly observed at the exit edge of a workpiece. A burr can cause premature failure of cutting tools, dimensional errors in manufactured components and serious problems in assembly. Deburring operation is usually employed for removal of burr. For reduction of deburring cost and time, burr reduction is essentially needed. The present investigation on drilling burr formation demonstrates an approach for burr reduction at the exit edge of the workpiece. A number of experiments has been carried out on low carbon steel flats under water soluble oil cooled environment to explore the influence of different exit edge bevel angles on burr formation under different machining conditions. At 20^o exit edge bevel angle, negligible burr is found at 0.2 mm/rev feed at all the cutting velocities considered and this condition may be adopted. However, with 25^o exit edge bevel angle, sizeable burr is obtained making it unsuitable.

Keywords

Drilling, Exit Edge Beveling, Wet Environment, Machining, Burr, Backup Support.

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Debjit Misra ¹, Santanu Das ¹, Nripen Mondal ², Partha Pratim Saha ³

Affiliations
1 Kalyani Govt. Engineering College, Kalyani- 741235, Dist. Nadia, West Bengal, IN
2 Jalpaiguri Govt. Engineering College, Jalpaiguri- 735102, Dist. Jalpaiguri, West Bengal, IN
3 Kanchrapara Railway Workshop, Eastern Railway, West Bengal– 731345, IN

Abstract

In drilling, the unwanted material adhered just beyond the hole produced in a workpiece material is known as a burr. In any conventional manufacturing process like drilling, milling, etc., machining burr is produced. There can be usually no conventional machining process which does not form burr. Presence of burr on the workpiece material leads to increasing production time as well as manufacturing cost. Minimization of burr height and thickness by changing machining process parameters and environmental condition yields decreasing production cost. The present work deals with prediction of burr height and burr thickness in the drilling process. An investigation has been performed by changing different process parameters like feed and cutting environment with respect to different drill diameters. From the experimental observation made by different sets of experiments with varying process parameters, minimum burr height and thickness are tried to find out. It is observed that using the back up support of the work material, burr height and thickness could be reduced remarkably. An Artificial Neural Network (ANN) model is developed using the experimental results. The neural network model estimates show close matching with the experimentally obtained results.

Keywords

Machining, Drilling, Burr, Estimation, Artificial Neural Network, NN, ANN, Modeling.

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