Tool paths planning under window framing scheme for burr minimization

A burr has been basically defined as a thin ridge or area of roughness produced in cutting or shaping metal. This burr leads to an undesirable workpiece edge that must be removed to enhance the level of precision of the parts. However, the cost of deburring precision components can be a significant addition to the cost of the finished parts. This paper presents a basic framework for a burr prediction system in end-milling based upon burr formation models, cutting condition, and analytical cutting force models, Wedeveloped a representation in a CAD framework to illustrate the machining process upon a PC-based NC simulator. This NC simulator can predict burr dimension and location in the end-milling process as a preventive measurement method. In addition, a tool paths planning scheme was included in the system to avoid tool exits. This method provides a feasible way for suppressing exit burr formation in an automatic manner, and thus reduce the need for deburring. The effect of in-plane exit angle was also discussed in this study. A systematic comparison of the predicted and measured burr size over a wide range of cutting conditions confirms the validity of the proposed method.