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Drilling Burr Formation with Tool Wear DRILLING BURR FORMATION WITH TOOL WEAR by Anna M. Mandra Master of Engineering, Aerospace Engineering, Ryerson University (2010) Bachelor of Engineering, Aerospace Engineering, Ryerson University (2007) A dissertation presented to Ryerson University in partial fulfillment of the requirements for the degree of Doctor of Philosophy in the program of Aerospace Engineering Toronto, Ontario, Canada, 2019 Copyright ©Anna M. Mandra, 2019 AUTHOR’S DECLARATION FOR ELECTRONIC SUBMISSION OF A DISSERTATION I hereby declare that I am the sole author of this dissertation. This is a true copy of the dissertation, including any required final revisions, as accepted by my examiners. I authorize Ryerson University to lend this dissertation to other institutions or individuals for the purpose of scholarly research. I further authorize Ryerson University to reproduce this dissertation by photocopying or by other means, in total or in part, at the request of other institutions or individuals for the purpose of scholarly research. I understand that my dissertation may be made electronically available to the public. ii DRILLING BURR FORMATION WITH TOOL WEAR Anna M. Mandra, 2019 Doctor of Philosophy, Aerospace Engineering, Ryerson University, Toronto (2019) ABSTRACT Automated assembly processes are being widely used in aircraft manufacturing as a hole must be drilled before fastener installation. Burr formation is of importance for machining processes including drilling. A burr, an unwanted by‐product of machining, is a raised edge that remains attached to a workpiece because of the loss of shear action. In drilling, burrs form as the drill enters and exits the part, particularly when the tool becomes worn. Burrs require an additional process to deburr, incurring extra cost and time. To understand drilling burr formation, this dissertation presents a new model that combines a burr model with a tool‐wear model. The first adopted model describes a burr with respect to its height and thickness and relates burr formation to the drilling thrust force generated from drilling with a sharp tool. This model comprises a number of key factors: part material property, tool geometry, and drilling parameters. In reality, these factors will vary. Preliminary work was done to use this model to develop a sensitivity matrix for the purpose of studying the effect of variation in the key factors on burr formation. Unfortunately, tool wear, which is a major issue, cannot be simply considered as a variation in tool geometry. When a tool becomes worn, the cutting edge radius becomes large, and the cutting action changes from shearing to ploughing. A second model adopted is a tool wear model, leading to the core work of this dissertation. The aim of this study is to develop a drilling burr‐formation model for realistic conditions, incorporating variance within the tool and process parameters. The proposed method applies a weighting model that can iii consider the wear/no‐wear condition for each segment, thereby leading to a hybrid model for drilling burr formation. The research method is validated through simulation and an experiment entailing the generation of drilling burrs in conditions mimicking those in aerospace manufacturing. The results show that the model successfully estimates burr height and thickness trends with increasing levels of tool wear, for penetrated holes. The methods and results presented in this dissertation show good promise for understanding the effects of tool wear on drilling burr growth. iv ACKNOWLEDGEMENTS First, I would like to thank my supervisor Dr. Fengfeng Xi, without whose support, encouragement and guidance this thesis would not have been possible. His comprehensive knowledge of machining and manufacturing was instrumental to what I have accomplished. I would also like to thank my co‐ supervisor Dr. Puren Ouyang, for his direction and helpful feedback during the course of this work. Thank you. I wish to express my gratitude to the defense committee consisting of Dr. O. Remus Tutunea‐Fatan from Western University, Dr. Seyed Hashemi and Dr. Bo Tan from the Department of Aerospace Engineering, and Dr. Ahmad Ghasempoor from the Department of Mechanical Engineering. Their insightful comments greatly improved the quality of this dissertation. I would like to thank Dr. Jeffrey Yokota, Graduate Program Director for the Department of Aerospace Engineering. Dr. Yokota’s enthusiasm and inspiration when I was contemplating graduate studies when I was still an undergraduate student and throughout graduate school, got me to where I am today. I would also like to thank Ryerson University for the various graduate scholarships and awards which helped support this research. Finally I would like to thank my dear parents and my amazing friends. You were always there for me with support, understanding and constant encouragement. Thank you. v TABLE OF CONTENTS AUTHOR’S DECLARATION FOR ELECTRONIC SUBMISSION OF A DISSERTATION ............................................. ii ABSTRACT ......................................................................................................................................................... iii ACKNOWLEDGEMENTS ..................................................................................................................................... v TABLE OF CONTENTS ....................................................................................................................................... vi LIST OF TABLES ................................................................................................................................................. ix LIST OF FIGURES ................................................................................................................................................ x LIST OF APPENDICES ...................................................................................................................................... xiv NOMENCLATURE ............................................................................................................................................. xv CHAPTER 1 INTRODUCTION ............................................................................................................................ 1 1.1 Introduction .......................................................................................................................................... 1 1.2 Background ........................................................................................................................................... 1 1.3 Objectives and Research Scope ............................................................................................................ 3 1.4 Thesis Organization ............................................................................................................................... 5 CHAPTER 2 BACKGROUND AND LITERATURE REVIEW ................................................................................... 6 2.1 Burr Formation ...................................................................................................................................... 6 2.2 Burr Properties ...................................................................................................................................... 8 2.2.1 Machining Burrs ............................................................................................................................. 8 2.2.2 Drilling Burrs ................................................................................................................................... 9 2.3 Deburring Processes ............................................................................................................................. 9 2.4 Influence of Parameters on Burr Formation ...................................................................................... 11 2.5 Impact of Tool Wear on Burr Formation ............................................................................................ 13 2.6 Slip‐Line Field Models ......................................................................................................................... 16 2.7 Drilling Burr Formation with Tool Wear ............................................................................................. 18 CHAPTER 3 DRILLING BURR FORMATION AND BURR SENSITIVITY ANALYSIS .............................................. 20 3.1 Drilling Burr‐Formation Model............................................................................................................ 20 3.2 Drilling Thrust Force ............................................................................................................................ 21 3.3 Material Deformation ......................................................................................................................... 23 3.4 Final Burr Formation ........................................................................................................................... 24 3.5 Model Validation ................................................................................................................................. 27 vi 3.6 Summary and Application in Subsequent Work ................................................................................. 30 3.7 Sensitivity Analysis of Burr Formation ................................................................................................ 30 3.7.1 Redefining Burr Height and Thickness ........................................................................................
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