Finite Element Modeling and Experimental Study of Burr Formation in Drilling Processes

Drilling is among the most significant manufacturing processes since it is widely used in the production of almost any product or part. Research in drilling processes and investigation of the phenomena that occur during the process is of great interest, given the fact that drilling is mainly applied at the final stages of the production process, thus it can greatly affect the total manufacturing cost. In the context of this study, a finite element model to simulate drilling and burr formation both on entrance and exit surface of the workpiece, was created. Simulation was implemented for the investigation of several combinations of cutting conditions, namely cutting speed and feed rate and the model was validated with a series of drilling experiments monitored by a high-speed camera.