Process and Tool development to deburr cross-drilled holes

该项目的目的是基于TRIZ （Teorija Reschenija Isobretatjelskich Zadatch -创新问题解决理论）的新工具概念，尖端几何形状和方法的开发，以实现可靠和自动化的交叉钻孔去毛刺。基于triz的开发方法是解决技术问题的系统化、结构化的方法。本课题研究的前提是对相交曲线与刃口几何的关系有更深入的了解。这将通过对不同直径的交叉钻孔的相交曲线、孔轴线之间的不对准以及预钻孔的旋转进行完整的数学描述来实现。随后，将分析相交曲线的梯度以及通过预孔或交叉孔的进入策略。对于不同的相交曲线，以及沿着单个相交的圆周，梯度变化很大，从而产生了现有去毛刺工具在去除整个毛刺根部时遇到的常见问题。一个球体代表所有的梯度，并且可以与沿轨迹的同步导轨结合使用，以补偿沿相交曲线的不同梯度。因此，一种可能的方法是使用球形或镰刀形的切削刃。实现了沿相交曲线圆周预测毛刺高度的模型，防止了大毛刺的弯曲。该方法的有效性基于从低毛刺形成区域开始的去毛刺过程。这种方法有助于可靠地去除毛刺。根据导出的描述孔交点的数学方程，将去毛刺工具沿相交曲线移动以去除毛刺。因此，基于工具和基于数控的方法将相结合，以实现工具和相交曲线的同步运动。随后，对不同进给策略、进给速度和切削速度对二次毛刺高度的影响进行实验研究。该研究项目的最后一年重点是开发一个模型，以确定去毛刺工具的操作范围，并研究切削刃的微观和宏观几何形状对二次毛刺的影响。

The aim of the project is the TRIZ- (Teorija Reschenija Isobretatjelskich Zadatch - Theory of Innovative Problem Solving) based development of new tool concepts, cutting edge geometries and methods for a reliable and automated deburring of cross-drilled holes. The TRIZ-based development method is a systematic and structured approach to solve technical problems. The prerequisite of this research project is a deeper understanding of the relationship between the intersection curve and the cutting edge geometry. This will be achieved through a complete mathematical description of the intersecting curves of cross-drilled holes with varying diameter, a misalignment between the axes of the holes as well as rotations of the pre-drilled hole. Subsequently, the gradients of the intersecting curves as well as entering strategies through the pre- or cross-drilled holes will be analyzed. The gradients vary strongly for different intersecting curves as well as along the circumference of an individual intersection, thus giving rise to the common problem existing deburring tools encounter when removing the entire root of the burr. A sphere represents all gradients and can be used in combination with a synchronized guide along the track to compensate the different gradients along the intersecting curve. Therefore a possible approach could be the use of a sphere- or sickle-shaped cutting edge. The implementation of a model used to predict the height of the burr along the circumference of the intersecting curve prevents the bending of large burrs. The efficacy of the method is based on the deburring process starting in areas of low burr formation. This method contributes to a reliable burr-removal. Based on the derived mathematical equations to describe the intersections of the holes, the deburring tool will be moved along the intersecting curve to remove the burr. Therefore a tool-based and a numeric control-based approach will be combined to achieve a synchronized movement of the tool and the intersecting curve. Subsequently, experimental investigations on the influence of different entering strategies, feed rate and cutting speed on the secondary burr height will be conducted. The final year of the research project focuses on the development of a model to identify the operating range of the deburring tool and to investigates the effects of the micro- and macrogeometry of the cutting edge on the secondary burr.