MICRO HOLE MACHINING WITH

MINIMUM BURR FORMATION USING

MICRO COMPOUND TOOL

SUBMITTED BY
TISS ISAC
S7 MECH
52

CONTENTS
Introduction
Literature Review
Objectives
Design of Micro Compound Tool
Experimental Method
Results and Discussions
Conclusion
References
2

INTRODUCTION
Conventional machining
Micro manufacturing
Burr formation is major problem in micro hole machining
Stainless steel is used as industrial

material for micro

machining
Necessity of micro tool for machining stainless steel

LITERATURE REVIEW
Churn et.al (2007) has inferred that existence of burr on
manufactured products could decrease product quality.
Imbibe et.al (2010) reported that stainless steel is the most
adopted industrial material in micro components.
Lining et.al (1998) proposed that assistance of ultrasonic
vibration could increase rigidity of drill and reduce drill
skidding.

OBJECTIVES
Development of new micro tool with capability of drilling and
finishing in one step process.

Effect of drill point angle.

Influence of ultrasonic vibration on the burr formation.

DESIGN OF MICRO COMPOUND

TOOL
Micro compound tool is a combination of micro flat drill as
drilling part and an electroplated part as grinding part

Fundamental design of developed micro compound tool

6

DESIGN OF MICRO COMPOUND

TOOL (contd)

Machining process using micro compound tool is divided into

four steps: preparation, pilot hole machining by drilling part,
grinding by tapered grinding part, hole finishing by grinding
part

Machining steps by the developed micro compound tool.

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EXPERIMENTAL METHODS
Two continuous process
-Fabrication of micro compound tool
-Hole machining with micro compound tool

Fabrication of micro compound tool

-grinding of micro flat drill as drilling part
-substrate of grinding part

EXPERIMENTAL METHODS (contd)

Machining of drilling part
and substrate for grinding part
Tool blank made of ultra-fine
cemented carbide having an
average particle diameter of
90 nm.
Diamond grinding wheel
clamped on main spindle.
Rotary table mounted on XY
table of machining center.
Grinding is performed in the
order of flank, cylindrical and
flute surfaces.

Machining of micro flat drill and

substrate for grinding part

 In the flank surface grinding, the rotary table, as well as the tool
blank, was rotated and fixed by an angle corresponding to the
desired drill point angle.
For the cylindrical surface grinding, the tool blank was ground
by feeding the grinding wheel linearly in the Z direction.
For the flute surface grinding, the fixed tool blank was rotated
and fixed according to the decided chisel edge and then it was
ground by feeding the grinding wheel linearly in the Z
direction.
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EXPERIMENTAL METHODS (contd)

Grinding condition
Grinding Wheel

Synthetic Diamond
Grit Number #3000
Outer Diameter 12 mm
Bonding Material Bronze

Tool Blank

Material ultra-fine cemented

Carbide. WC particle size: 90 nm
Initial Diameter 1.05 mm

Target Geometry

Drilling Part
Diameter
Flute Length
Point angle
Clearance angle
Chisel edge angle
Web thickness
Back taper
Grinding part
Substrate diameter
Substrate length
Grinding part taper

Grinding condition
Rotor speed
Feed rate
Coolant
Dresser type

90 m
300 m
100-130
16
115
50 m
5/100
90 m
300 m
10/100

4200 min-1
100 m min-1 for flank and periphery grinding
50 m min-1 for flute surface grinding
Water based coolant
GC type dresser. Grit size of #3000

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EXPERIMENTAL METHODS (contd)

Electroplating of grinding part
Process- cleaning of substrate, masking, strike plating by
nickel for 2 min, electroplating of diamond grits and
embedding them into the electroplated layer.

Electroplating of grinding part

Bath

Ammonia citrate
bath
Ni(so3)2H20
(NH4 )10 W12 O41
5H2 O
C6 H5 O7 (COOH)3

Strike plating liquid

sulfuric acid and

Nickel sulfate

Strike plating period

2 min

Diamond grit
diameter

24 m

Stirring method

Automatic
intermittent
stirring

12
Current
density
2conditions.
A dm2
Electroplating

EXPERIMENTAL METHODS (contd)

Through hole machining
Metal shim tape which is made of SUS304 was selected as the
work piece.
USV table providing the vibration to the work piece is installed
on the XY table.
To provide a high rotational speed, a high speed motor driven
spindle was fixed on the Z axis of machining center.
In hole machining without ultrasonic vibration, the work piece
was clamped on the jig having some pilot holes which was
installed on the XY table of machining center.

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EXPERIMENTAL METHODS (contd)

In hole machining with ultrasonic vibration, work piece was

clamped on jig which was vibrated with natural frequency and
double amplitude of about 63.5 kHz and 1.5 m.

Hole machining condition

Hole machining with USV 14

RESULTS & DISCUSSIONS

Fabricated micro compound tool

Comparison of the burr condition

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RESULTS & DISCUSSIONS (contd )

Surface roughness comparison of the hole inner wall

The developed micro compound tool decrease the burr size both
at the entrance and exit holes.
Improved the hole wall surface significantly.
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RESULTS & DISCUSSIONS (contd )

Effect of ultrasonic vibration

Burr formation at 100th hole in

hole machining

Burr comparison between drilling

with and without USV
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RESULTS & DISCUSSIONS (contd )

The hole entrance, burrs under both conditions seems equal in

size but it is significantly different at the hole exit.

For both conditions, as the number of holes is increasing, burr

width and height are also gradually getting larger.

In machining without ultrasonic vibration causes a very

progressive increase of burr width and height compared to
machining with ultrasonic vibration.

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RESULTS & DISCUSSIONS (contd )

Effect of drill point angle

Fabricated micro compound tool with different point angle

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RESULTS & DISCUSSIONS (contd )

There

is

no

significant

change in entrance burr for

both burr width and height
although the number of
hole is increasing.
At the hole exit there is a

very significant difference

among them.
Burr formation

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RESULTS & DISCUSSIONS (contd)

Burr for different drill point angle

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RESULTS & DISCUSSIONS (contd)

Drill point angle of 100 produced the largest burr width and

height compared with other two point angles.

On the other hand, drill point angle of 118 formed almost a

stagnant growth of burr width and height even the number of
hole is progressing.

Drill point angle of 130 resulted in significant changes of burr

width and height.

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RESULTS & DISCUSSIONS (contd)

Tool wear comparison with different drill point angles after drilling

It can be observed clearly that the tool wear is growing faster as

the drill point angle is getting larger.

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CONCLUSIONS
Micro flat drill is developed by fabrication of micro flat drill
and electroplating.
Micro compound tool decreases the size of burr
Application of ultrasonic vibration

reduces the plastic

deformation and enhances the performance of the tool.

Burr formation is restrained and the tool life increases as
machining force decreases
Tool with drill point angle of 118 is considered as the best
geometry because it forms burrs in smaller size stagnantly and
showed a moderate tool wear

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REFERENCE
Muhammad Aziz a, , Osamu Ohnishi b, Hiromichi Onikura
b 2011. Innovative micro hole machining with minimum
burr formation by the use of newly developed micro
compound tool
Koi SL, Lee JK. Analysis on burr formation in drilling with
new concept drill. J Mater Process Techno 2001;113:392
8.
Chang SSF, Bone GM. Burr size reduction in drilling by
ultrasonic assistance. Robot CIM-Into Manu 2005;21:442
50.
Churn GL, Engine Wu YJ, Cheng JC, Yao JC. Study on burr
formation in micro-machining using micro-tools
fabricated by micro EDM. Precision Eng. 2007;31:1229.
Allen DM, Shore P, Evans RW, Fanfare C, OBrien W,
Mason S, et al. Ion beam focused ion beam and plasma
discharge machining. CIRP Ann Manu Techno
25
2009;58:64762