Burr Minimization in Shaping of Aluminium Alloy-Through Experimental and Stress Analysis Approach

Abstract:

Shaping Burrs are produced at the edge of a workpiece when a cutter exits it. It causes difficulties in manufacturing and assembly stages. Several attempts were made to minimize burr to suppress deburring to improve productivity. Deburring of the surface in shaping operation in railways industry and other industries is a great problem. An investigation on burr formation at the exit edge of aluminum alloy (4600-M) flats in shaping operation is done in this work under dry environment. It is found out that burr is negligible at 15⁰ exit edge bevel angle. Distribution of shear stress is analyzed using FEM to validate the experimental results. It is found that maximum equivalent stress and deformation at different points on the 15⁰ exit edge bevel angle become minimum justifying the experimental observation. Hence, an exit edge bevel of 15⁰ may be adopted to have minimum burr formation.

• Periodical: Applied Mechanics and Materials (Volumes 117-119)
• Pages: 1602-1605
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.117-119.1602
• Online since: October 2011
• Authors: Atanu Das, Partha Pratim Saha, Santanu Das
• Keywords: Edge Beveling, Exit Edge, Finite Element Method (FEM), Machining Burr, Negative Shear, Shaping

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