An Experimentalapproach to Investigate the Effect of Process Conditions on Exit Burr formation in Shapingan Aluminiumalloy

At the exit edge of the wokpiece, burrs are usually found during shaping operation. Gradual rotation of the positive shear plane to the negative shear plane may be the reason behind it. This is due to absence of any support material at the exit end of cut. In the present work, a number of orthogonal shaping experiments is performed on aluminium alloy (4600-M) in dry environment under different cutting velocities, orthogonal rake angles and exit edge bevel angles to observe the occurrence of burr formation. Experimental results are analysed through ANOVA to find out the significance of the effect of cutting parameters and exit edge bevel angle to control the exit burr formation. It is noted that exit edge bevel angle has the most significant effect. An exit edge bevel angle of 15° is recommended in shaping operation when burr becomes negligible.