Edge finishing planning in milling

Manufacturing precision mechanical components often requires an edge finishing operation. Deburring automation has been the prime objective for many researchers and companies. However, the concepts of burr prevention and minimization are often overlooked. This dissertation focuses on many aspects of edge finishing planning in milling using a systems approach. Adjustments in machining process plan and deburring plan are taken into account.;The software for burr prediction is developed for planar parts under a milling operation. The output of the software is an edge finishing report file which can be used for deburring planning as well as process plan evaluation. Another stand-alone software is developed to view this report file graphically.;In milling, the in-plane exit angle has always been the critical parameter to determine burr formation. Thus, an algorithm is developed to generate a milling tool path in such a way that exit burr formation is avoided. The entrance burr is generally smaller and can be minimized through the selection of other process parameters.;From the deburring planning point of view, the deburring process/equipment that is capable of deburring parts to the tolerance specification at a minimal cost should be selected. The deburring cost depends largely on the deburring tool feed rate, which, in turn, is a function of burr size profiles on the part. Here, the two most widely used processes, chamfering and brushing, are considered. A sensitivity analysis of the total deburring time on burr size profile is also performed.;In concluding the strategies for minimizing deburring cost, several approaches that can be taken at the process planning level include (1) minimizing machining burr, (2) locating burrs on easy-to-access edges (by the deburring tool), and (3) minimizing burr size variation. As to deburring planning, the improvement of currently used deburring processes is achieved through efficient deburring tool paths and selection of the deburring process parameters. The deburring tool path planning scheme is set up as a Traveling Salesman Problem, and solved using a commercial software package, CPLEX. Furthermore, the strategic aspect of the "when" to improve or adopt the new deburring process to the production line is discussed.