Development of a combination tool for drilling and deburring cross-drilled holes and complex hole exits

• Applicant: Professor Dr.-Ing. Eberhard Abele
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2021
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 459510445

As part of the preceding basic research project „Method and tool development for deburring cross-drilled holes“ a method was developed which enables the reliable deburring of cross-drilled holes on machining centres. The method calculates ideal tool-workpiece interactions using mathematical calculation specifications and has significant advantages compared to conventional mechanical deburring tools. The mathematical representation of the intersection curve of main and cross hole and the calculation of the adapted tool path for modified ball head tools enables deburring and constant attachment of chamfers at almost all possible bore intersections and bore exits. During the knowledge transfer phase, the acquired knowledge and skills are to be transferred to industrial applications. Using the TRIZ development methodology it was determined that cemented carbide drilling tools with geometric adaptions (back grinding in the area of the drill shank) can be equipped with additional cutting edges that enable the deburring process. In combination with a path calculation as developed in the previous basic project the drilling process and deburring process can be integrated in an integrated tool. The aim of this project is the development of a combined drilling and deburring tool as well as an associated method for path calculation which enables drilling and subsequent deburring of cross-drilled holes and complex bore exits. The development is to be tested for the materials AlSi7Mg and 42CrMo4V. Drill-deburring tools for four different cross-drilled holes with different deburring difficulties are to be developed.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Gühring KG
• Co-Investigator: Professor Dr.-Ing. Matthias Weigold