A review on the study of burr formation in the

sheet metal
 Nitesh kumar Praveen kumar 3rd Author
Delhi institute of tool Delhi institute of tool 3rd author's institute
engineering engineering affiliation
8178195098 9899399004 Telephone number
[email protected] [email protected] 3rd E-mail address
m om
 Abstract side is adjacent to the Hakan et al. [2] produced part with the
break. The burr side is so experimentally examine specified dimensional and
There are a lot of defect called because, if a the effect of punch angle form tolerances and to
produce during cutting noticeable burr condition shearing force using warm product design on
the sheet in automotive develops. Burr should be fuzzy logic. The punches the process limitation as
industry. Burr formation practically nonexistent if used in the test are well.
is one of them. Usually the cutting clearance machined using wire J. Mocha [5]
burr formed in every between the punch and EDM for angles of 0°, 2°, experimentally
cutting operation. the die is correct and if 4°, 8° and 16°. Six investigated the analysis
Industrialist always seek the cutting edge are different matrices were of the effects of various
to minimize the burr sharp. In fact when a die used with clearance rates material tool’s wear on
formation by some is running in production, of 0.4%t, 0.5%t, 0.6%t, burr during generator
medium. This paper the degree of burr on the 0.7%t, 0.8%t and 0.9%t. sheets blanking. The
describe that what piece parts is an The test results signify following conclusion was
preventation we can take indication whether the die that shearing forces can found that, the analysis of
while shearing and is ready for sharpening. be reduced by 80 % when the tool wear influence
cutting the sheet metal, a 16° punch angle is used. allows for the monitoring
punch shear angle and The punch clearance is of the blanking operation,
cutting edge play a vital 2. Literature on observed not to have as and so, the parts quality
role in reducing the burr burr formation significant an effect as variations during the
side generation area . the punch angle did with forming process may be
This paper also clears that Xin et al. [1] studied shearing force. predicted. The main wear
what practices can about the characterization Vanditake et al. [3] mechanism of the punch
increase the tool life & of mechanically shaded analysed an overview of flank is abrasion wear.
how long we produce edges of dual phase steel. effect of punch tool wear Tiny slugs may adhere to
“burr free” parts. It also The following conclusion radius on burr formation the machining marks on
include some discussion was found that Roll-over in sheet metal blanking. the punch flank while
by which tool life can height increases with die The following conclusion using the grinding punch.
increase. clearance, decreases with were found that burr Thus, the grinding
. material strength, and formation in sheet metal process is not suitable for
increases with shearing blanking is greatly punch machining in the
1. Introduction orientation relative to affected by wear radius. high-speed progressive
RD. Burr height increases As wear radius increases die. Tools made of
In automobile industry with die clearance, burr height also increases, tungsten carbide have
the R&D department decreases with material so to have quality been found to have the
always try to find the low strength (not so clear blanking product wear best wear resistance
cost and best method to between DP600 and radius should be among the tool materials
obtain maximum DP780), and increases minimum. and tool coatings being
production. Press tool is with shearing orientation Umaras et al. [4] investigated. The quality
parent area where we can relative to RD, though the investigated that the of sheet metal blanking
work on to minimize the effects are rather weak factor of influence in the can be checked by
production cost by Roll-over height dimensional and form quantifying the relative
optimum waste of sheet increases with die precision of stamping importance of the roll-
metal. Application of clearance, decreases with processes. The following over, sheared and fracture
sheet metal components material strength, and conclusion was made, the zones, and burr height.
includes Aircraft industry, increases with shearing tolerances specified in the Quality is all the better as
Automobiles, orientation relative to detail drawings of parts the sheared zone is
Construction work and RD. Fracture zone height must be met by the important in the blanked
many other applications is reversely related to the production processes, as part edge profile, as this
such as appliances, food burnish height since these tight as possible. In order accompanied by the
and beverage containers, two zones occupy to provide both tool and smallest zone of material
boilers, kitchen majority of the sheet total process developers with microstructure changes.
equipment, office thickness. the parameters needed for Gao et al. [6] presented
equipment etc. The burr compliance of the that the microstructural
characterization of aluminium alloy which application of the cutting die with finite element
aluminum alloys using includes pure aluminium, fluids. method. Based on the
Weck's reagent. The heat treatable aluminium M.Bhavar et al. [9] simulation results using
following conclusion was alloy and non-heat Examine the PVD the scheme and the
made that With the help treatable aluminium alloy. Coating Used in Piercing experimental results, the
of Weck's reagent, the Due to the great and Operation for Improving following conclusions
micro-segregation that versatile properties of Tool Life. The following drawn that, On the test
occurred simultaneously aluminium alloy, the conclusion was found results, through analysis,
with the growing of demand of usage for the that the very less work the clearance was the
grains during water aluminium alloy had has been done in the field most influential factor of
quenching could be improved vastly in so of Piercing Punches the mold parameters in
visualized So that solid many applications. The about its life. In sheet piercing process and it
fractions for certain semi- two main industries that metal Industries punches was followed by punch-
solid temperatures could benefit most from are worn out, to improve die round radius. While
be more accurately aluminium alloys were its life coating is one of the interaction of
evaluated with the the automotive and the methods which clearance and punch-die
exclusion of the area aerospace industries. The applying for it. The tool round radius had almost
corresponding to the use of aluminium alloys wear in punching, tool no effect. The results also
grain growth. Compared ensure a brighter future wear affects tool life also showed that the punch-
with other methods, using since its usage is almost work on punch and die die round radius had little
Weck's reagent is not limitless and ensures a clearance for affecting influence to the real crack
only accurate, but also more sustainable and tool life. Hard coating for propagation and ideal
very economic and time- greener environment. blanking and piercing crack propagation
saving. The influence of Silva Costa et al. [8] tool also optimization of showed a slow declined
etching time on the result experimentally examine PVD coated on EN31 tendency. The numerical
of usingWeck's reagent. the burr produced on the alloy steel in dry experiment results
The result showed that drilling process as a conditions. showed that the best
etching for 12 s yielded function of tool wear and A. Mamat et al. [10] clearance could be got
to the best result. Also, by lubricant-coolant experimentally when the ratio of
repeating the polishing– conditions. The following investigated that Burr clearance and thickness
etching process with the conclusion was found formation characteristics of material was 14%.
same etching time, we that height of burr of various engineering Pravin et al. [12] in this
examined the re- increase with drill wear. materials in micro literature reason for the
poducibility of Weck's The cutting speeds of 45 milling. They concluded breakdown has been
reagent. Although there m/min and 60 m/min that the Burr-breakage analyzed and inspected
was some tiny change of produced relatively type of burr more by using Fish bon
color, the color revealed similar average burr significant in less ductile diagram by this analysis
for each time of etching heights for all the material. Minimum depth root causes of breakdown
was quite stable. lubricant/coolant of cut for micro were identified. After root
S. N. M. Yahaya et al. [7] relatively alike average machining is half of tool cause analysis
presented a review paper burr heights for all the cutting size. Small depth availability, Mean time
in the aluminum alloy lubricant/coolant systems of cut will cause the between failures
series and its up to about 64% of drills plowing mechanism increased 4.16%, 13.66%
applications. The life, the average burr instead of shearing and Mean time to repair
following conclusion was heights for the speed of therefore burr size is (MTTR) decrease
made that the several 45 m/min were high. The higher depth of 46.42%.
available types of practically twice those for cut, the higher burr size
aluminium alloys were 60 m/min . Burr occur. Burr size of ductile S. Sathishkumar et al.
presented and explained. formation is indeed material relatively high [13] presented that the
Each series of the linked to the capacity of compared to less ductile design and development
aluminium alloy is based the tool to continue material of special purpose
on its alloying element. cutting even after high Yang Yanxiong [11] machine using hydro
There were 3 main wear levels, which is studied about the pneumatic cylinder to do
classes of all the series in make certain by the parameters of piercing 4 holes and 2 holes
piercing in a square tube. characterization including due to its complexity of thickness guide to
They observed that the, specialized burr sensors. geometric shape and substantial burrs and
Piercing tools are Development of larger thickness, and thus lower formability. DP980
developed with indexing specifications and should be avoided. The steel demonstrated
method by piercing one standards for burr value of the censorious substantially different
or two holes at a time and description and depth of cut for the behavior compared to
then by locating first hole measurement. fracture strain of the work earlier published results
and do piercing of other H. shin et al. [15] material. on DP500 and DP600
holes. This needs 75/100 presented the burr control J.Barik et al. [17] steels forming nearly no
ton press and 6 strokes. in meso punching process investigated that the burr burrs in the range of
Also the position of holes .The following results formation and shear cutting clearances up to
accuracy can vary due to they were found, in meso strain field evolution 40% thickness. Sheared
location of problem. By punching system they studies during sheet metal edge stretchability
making 6 strokes for one introduced two kinds of blanking. They conclude measured in diffuse
part only 50 parts can be punch die auto aligning that the Finite element necking area and in hole
produced (300 strokes per methods, the punch die simulation of blanking expansion test illustrated
hour) and 400 parts per contact sensing method provides platform to that the best stretchability
shift against the and the in situ self- understand the effect of can be obtain for the
requirement of 2000 parts aligning method, to various input geometric cutting clearances 10…
per shift. The material is uniformize and minimize parameters like clearance, 15% t.
produced with minimum the burrs produce during punch edge radius, die K. kutuniva et al.[19]
usage of energy and the punching process. edge radius and sheet studied the effect of
accuracy of the produced They also use laser burr thickness, etc. on burr convex sheared punch
component is improved. measuring system for height in comparison to geometry on cutting force
J.C. Aurich et al. [14] precise measuring of burr experimental methods. of ultra -high strength
experimentally but burr measuring Burr height is highly steel (UHSS). In this the
investigated that the burrs conclusion would have sensitive towards the convex two-way sheared
—analysis, control and uavoidable error caused change in punch edge punches were compared
removal. They concluded by the size effect of the radius and clearance. to the punching forces of
that, Future development laser spot when the burr Overall an increase in the traditional flat end
for comprehensive and did not have enough size. punch edge radius and punch. The following
integrated strategies for Gwo-Lianq Chern [16] clearance increases the conclusion was drawn
burr minimization and present that Experimental burr height The Pattern of that the cutting forces of
prevention will depend observation and analysis shear strain field the ultra-high-strength
on the continued of burr formation evolution across the shear DQ960 can be reduced
development of mechanisms in face zone shows the radically by using the
predictive models with milling of aluminum probability of occurrence optimal shearing angle of
powerful databases, alloys. The following of fracture initiation near the tool large shearing
including ‘‘expert data thing they found that the the punch side. angle. The punch caused
bases’’ for process in-plane exit angle Sergey et al. [18] studied some negative aspect to
specification. Simulation strongly prestige the about the trimming and the quality of the hole.
models of burr formation geometry of the burrs in sheared edge The best compromise
capable of indicating the face milling. Five types stretchability of light between the force
interaction and of burrs were built in the weight sheet metal contraction and the
dependencies of key experiments on aluminum blanks. The following cutting quality was the
process parameters for alloys: knifetype, wave- conclusion was made by shearing angle of 7°.
burrs at all scales. type, curl-type, edge them Sheared edge U.P. Singh et al. [20], in
Strategies for burr breakout and secondary stretchability and burr this paper the study of the
reduction linked to burr. Formation height of Aluminum sheet problem was done by
computer-aided design mechanisms of each type 6111-T4 has strong using the finite-element
and process planning of these burrs are fully vulnerability upon the technique. 3-definite-
systems. Inspection discussed. Wave-type cutting clearance. element models of
strategies for burr burr will increase the Increasing the cutting numerous types of
detection and difficulty of deburring clearance to 40 % punching/blanking tools
were developed; these the same press or to conclusion were found, the pierced holes. Other
models facilitate the permit the use of a this paper presents a SPH parameters demonstrated
analysis of the effects of lower-rate coupled FEM method to significantly lower
variations in tool Since the admittance of simulate the blanking effects. Bigger clearance,
geometry on the eccentricity due to proces. A hybrid larger laminate thickness,
punching/blanking force asymmetric load on the approach that used the and lower cutting edge
and on the deformation of press is an important SPH formulation in the radius result in lower
the punch, a parameter factor in the shearing zone with high cutting resistance. The
highly relevant to the punching/blanking material distortion and observed effects of the
assessment of tool work process the choice of the Lagrangian process parameters on the
in terms of the accuracy punch with balanced formulation in the region cutting resistance of
of the manufactured convex shear, against away from the highly CFRP laminates tally
components. The punch with sintered hard distorted zone was very with that of metals.
miniature catered also for metal around its strong and reliable. Based Cherkasova et al. [24]
variation in the circumferential cutting on the experimental data, studied the mechanism
characteristics of the tool edge, is obvious though the model had been and kinetics of wear of
material, in the sense that the axial stiffness of shown to be able to shearing dies from semi
a highly wear-resistant punched sintered hard provide adequate heat resistant steels in
tool is normally poised metal having a estimation of the machining articles made
of carbide tips around its substantially greater punching forces, de- from various structural
cutting profile. Computed competitive edge than formation state of materials. .The following
results from FE miniature punch balanced convex material and might be results they were found,
were checked against shear. used for process control the complex studies of
design standards by the Pk Rai et al. [21] studied as well as optimizing the shearing die operation
American Society of the causes & preventation blanking parameters. and fracture during
Manufacturing Engineers of defects (burr) in sheet Actual investigations machining of low car bon
(SME). Some suggestions metal component. The concern the simulation of steel, aluminum alloy,
are offered as to how the following conclusion blanking, in which the and corrosion resistant
efficiency of a were drawn, flatness of tools can’t be considered and carbon steels that are
punching/blanking tool all the blocks which as rigid bodies. used in sheet metal
can be enhanced. That should be maintain in Klocke et al. [23] stamping allowed us to
the radial deformations of 0.02 – 0.05 mm. Surface experimentally systematize the wear
punches with balanced of the block should be investigated that the hole mechanism. They
convex and concave grinded. 2D machining accuracy, delamination, propose the following
shear have a minimum i.e. all bolt & Dowell and cutting force in typical variants of wear
value within the shear holes should be at your piercing of carbon fiber resistant coatings to
angle range of 17°-22 ° right position. Clearances reinforced plastics. . They provide better efficiency
advise that a shear angle of die and punch should concluded that the of the working elements
of 20° can be suggested be proper at the time of diameter of pierced holes of shearing dies with
safely for practical EDM wire cut. At the was always smaller than different loads and wear
purposes. Amongst the time of assembly, equal the punch diameter. mechanisms, namely, Ti/
rigid characteristics tightening force should Higher dimension (Ti,Zr)N, Cr/CrN,
appraise for all types of be given alternately to deviations were observed TiN/TiCN/(Ti,Cr)N, and
punches, the punch with each bolt. Hole & shaft for thicker laminates and Ti/(Ti,Al)N.
balanced convex shear tolerances should be bigger punch diameters. Levy et al. [25] presented
shows the best applicable in all sliding, Higher blank holder review of the shearing
performance advise that push fit holes. pressure and sharp process for sheet steels
this type of punch can L.Bohdal [22] presented cutting edge improve the and its effect on sheared-
reasonably be favored in the application of the dimensional accuracy. edge stretching. The SAZ
practice in order to smoothed particle Punch diameter had the controls limit strain for
reduce the stress on the hydrodynamics (SPH) highest influence on the sheet steels in sheared
tool and thus to enable method to the simulation form accuracy. Smaller edge stretching.
thicker or more resistant and analysis of blanking punches resulted in Deformation in the SAZ
stock to be punched on process. The following higher form accuracy of was the dominant factor
in reducing the failure optimum energy of press Indexing", in Proceedings
limit for sheared-edge tool is also discussed. 25th IEEE/ACM
stretching, while voids Types of burr formation International Conference on
Software Engineering
and micro cracks have a also explain in it. The
(ICSE'03), Portland, OR,
secondary effect. The current paper gave a May 3-10 2003, pp. 125-
depth of the SAZ was semi-comprehensive and 137.
less than the sheet up-to-date review of
thickness and was these processes. Finally, [5] Salton, G., Automatic
Text Processing: The
probably less than half the discussion covered
Transformation, Analysis
the sheet thickness. recent trends in and Retrieval of Information
Shearing variables and automotive of these by Computer, Addison-
material properties affect conditions and provide Wesley, 1989.
the depth of the SAZ. The potential for future
transition from burnish to developments.
fracture regions on the
shear face occurs when
the stress becomes
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