Burrs severely inhibit the performance and aesthetics in machined parts besides posing a safety risk to the user and manufacturer. Abrasive assisted brushing presents a fast and effective method for deburring these parts but is difficult to control. The dependence of deburring rate on the workpiece material, abrasive grit size, type and rotational speed of the brush is studied. It is found that deburring rate is proportional to initial burr height indicating fracture of the burr at the root. Deburring rate increases with spindle speed and is higher for diamond than SiC. The formation of burrs in micromilling of a thin nickel-titanium alloy (nitinol or NiTi) foil used in implantable biomedical device applications is analyzed as a function of micromilling process parameters such as spindle speed, feed, tool wear, backing material and adhesive used to attach the foil to the backing material. All factors except spindle speed are found to affect burr size. If initial penetration is sufficient to cause the foil to fail in tension, the foil tears with the crack starting closer to the upmilling side and thereby resulting in larger downmilling burrs. If penetration is insufficient, the foil plastically deforms until it tears typically in the middle of the cutter tooth path. A kinematic model that captures this behavior is used to predict burr widths and is verified through experiments. The thesis also presents an investigation of the abrasive impregnated brush deburring process for thin NiTi foils. Models based on Hertzian indentation and fracture mechanics are proposed to predict the rates of indentation and deburring during brushing and are validated using experiments. The predictions of the models are within the experimental variation. Burrs can be removed with this process within 12 minutes for a 6 mm long groove with no more than a micron change in foil thickness. Knowledge of burr formation and deburring is applied to a novel micromilled thin shape memory based NiTi foil device used for the surgical correction of Age-related Macular Degeneration (AMD), a leading cause of blindness in the western world in those over age 50. Burrs on the surface of the structure are used successfully to mechanically constrain and translocate an autograft to replace the diseased RPE-Bruch's membrane under the macula. The shape memory device is analyzed using experiments and simulations.

<p> Burr formation is a frequent problem in metal cutting. Burrs, which are defined as undesired projections of material resulting from plastic deformation, affect the precision of machined components and can negatively affect the assembly process. One common burr is the exit burr that forms when drilling ductile materials such as aluminum alloy. Deburring, the process of removing burrs, can account for up to 30% of the total production cost. If the burr size can be reduced, the deburring effort can also be reduced or even eliminated, resulting in an improvement in productivity and an increase in profit. </p> <p> There are different methods to reduce burr formation in drilling. One method is known as vibration assisted drilling. Vibration assisted drilling has been reported as an effective method to reduce burr height without reducing the material removal rate or permanently altering the mechanical behavior of the workpiece material. Other reported benefits of vibration assisted drilling include improvement of tool life and better machined surface quality. However, it has been reported that poor choice of vibration conditions (frequency and amplitude) can increase burr height. No accurate analytical model exists in the current literature that can predict the exit burr height for vibration assisted drilling. To predict exit burr height, a model capable of predicting thrust force accurately is important because higher thrust force produces larger exit burr. Clearly there is a need to develop these models. </p> <p> This thesis presents the development of analytical models for predicting thrust force and exit burr height for vibration assisted drilling of aluminum 6061-T6. The developed models incorporate all significant characteristics of vibration assisted drilling to achieve accurate predictions. Drilling experiments were performed over a range of cutting and vibration conditions. The experimental results demonstrate that the developed thrust force model improves the accuracy by up to 45% in comparison to the existing vibration assisted drilling models. The developed burr height model accurately predicts the exit burr height for vibration assisted drilling, with an averaged deviation of 10% from the experimental results. The developed models are also applicable to conventional drilling. Comparing with the existing drilling models, the new models improve the accuracy of thrust force and burr height predictions by 6 and 36% respectively. A fast analytical method has also been developed that predicts the favourable vibration conditions that minimize burr height. The predictions obtained using this method are consistent with the experimental results. Drilling experiments for combined frequency vibration assisted drilling were also performed over a range of vibration conditions. The experimental results demonstrate that combining two different favourable vibration conditions together produces greater mean thrust force reduction than using a single frequency vibration assistance. </p> / Thesis / Doctor of Philosophy (PhD)

Burrs are rough protrusions that form along the edge of a component during processing and are commonly produced during machining. Generally, the presence and severity of a burr directly impacts the final part quality. Thus, burrs need to be removed in subsequent processes to avoid injury when handling a part and/or negatively impacting the part's functionality. The size, shape, and nature of the attachment of the burr to the cutting edge are highly dependent on the material, tooling, and process parameters used during machining. This research aimed to develop two new approaches to minimize and/or eliminate burr formation during the drilling of ductile materials. The first new method outlined in this thesis relates to injecting materials in different forms at high pressures under the workpiece on the side from which the drilling tool exits to support the drilling thrust force and thereby minimize exit burr formation. The second method introduced a novel technique for designing and testing highly effective step drills based on the workpiece material and cutting parameters, using commercial drills. Testing the two approaches showed promising results for producing comparatively smaller exit burrs. / Thesis / Master of Applied Science (MASc)

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The physical and mechanical characteristics of carbon fiber reinforced polymers (CFRP) and Ti6Al4V make them widely used in the aerospace industry. The hybrid structure of CFRP/ Ti6Al4V material has been used in the new generation of aircraft manufacturing. The drilling process of these materials is often associated with unfavorable machining defects such as delamination, burr formation, reduced surface integrity, and tensile residual stresses. These machining defects are attributed to high thermal load, continuous chip morphology, and poor chips evacuation efficiency. Vibration-assisted drilling (VAD) uses an intermittent cutting process to control the uncut chip thickness and chip morphology. VAD has potential advantages include low thermal load, high chips evacuation effectiveness, and longer tool life. This thesis presents an experimental investigation into the effect of VAD machining parameters on the cutting energy, CFRP delamination, surface integrity, geometrical geometry, Ti6Al4V burr formation, induced residual stresses, and tool wear during the drilling process of CFRP, Ti6Al4V, and CFRP/Ti6Al4V stacked materials. Moreover, a kinematics model is developed to link the observed results to the independent machining parameters (i.e., cutting speed, feed rate, modulation amplitude, and modulation frequency). The experimental work covers a wide range of machining parameters using four levels of frequencies (83.3, 125, 1500, and 2150 Hz). The VAD results show up to 56 % reduction in the cutting temperature with a significant enhancement in the CFRP entry and exit delamination, geometrical accuracy, surface integrity, and burr formation. The use of VAD also generates compressive stresses, hence improving the part fatigue life. / Thesis / Doctor of Philosophy (PhD)

Dans un contexte d’optimisation des lignes de production, la maîtrise de la qualité des pièces et des capacités machines est primordiale. Plusieurs études se sont intéressées à la formation des bavures en usinage mais les mécanismes sont encore peu connus, bien qu’un lien fort avec les efforts de coupe soit établi par divers auteurs. Ainsi, la maîtrise des efforts de coupe a un intérêt double : optimiser les lignes de production et servir de donnée d’entrée pour la prédiction de la taille des bavures. Cette étude propose donc de renforcer les connaissances concernant les mécanismes de formation des bavures générées par un outil en sortie matière, et de prédire les efforts de coupe en fraisage grande vitesse, dans l’alliage d’aluminium AlSi7Mg0,3+0,5Cu. Divers mécanismes de formation de bavures sont étudiés en coupe élémentaire. Une nouvelle méthode de mesure in situ permet d’identifier l’influence des conditions opératoires sur l’évolution statistique de critères géométriques caractérisant les bavures générées de façon hétérogène dans le cas de l’alliage étudié, dont le comportement est fortement dépendant de son état de contrainte local ainsi que de sa microstructure. Une analyse des champs de déplacement et déformation par corrélation d’images couplée ainsi qu’un modèle de simulation par éléments finis permettent d’identifier plus finement les mécanismes de formation des bavures. Le surfaçage est étudié pour modéliser les efforts de coupe puis comparer les efforts produits lors de la sortie des dents avec les caractéristiques des bavures obtenues. Enfin, une stratégie de minimisation de la hauteur des bavures en surfaçage à la fraise grande avance est étudiée. / In a context of production lines optimization, parts quality and machine capabilities control is essential. Several studies have been carried out on machining burr formation but the mechanisms are not fully understood, although a strong link between burrs formation and cutting forces is established by several authors. Hence, controlling the cutting forces has two advantages: optimize the production lines and be used as input data for a burr height model. This study proposes to consolidate the knowledge on burr formation mechanisms during the exit of a tooth, and to predict cutting forces during high speed milling of the AlSi7Mg0.7+0.5Cu alloy. Various burr formation mechanisms are studied in orthogonal cutting. A new in situ measurement method allows to identify the statistical influence of some operational conditions on the evolution of some newly introduced geometrical parameters defining the burrs heterogeneously formed in the case of the studied alloy, whose behavior strongly depends on its local stress state as well as its microstructure. A displacement and strain field analysis using Digital Image Correlation, as well as a finite element model provide a better understanding of the burr formation mechanisms. Face milling is studied to model cutting forces and compare the forces produced during the exit of a tooth to the obtained burr morphologies. Finally, a burr height reduction strategy is proposed using a high feed mill.