Analysis of the effects of process parameters on exit burrs in drilling using a combined simulation and experimental approach

Experimental modeling of burr formation processes has received limited industrial application. This limited use is due to the large number of parameters in the experimental design resulting in a large number of experiments and high costs. This paper presents a methodology to combine experimental, simulation, and statistical tools to reduce the time and cost of parameter studies. The statistical analysis is based on an experimentally verified simulation that predicts burr height, force, heat flux, and temperature at breakthrough. The analysis is based on parameters typical of 2024-T351 aluminum and 7075-T6 aluminum. Parameter interactions are also considered. The results of this study compare well to experimental studies presented in the literature.