Modeling and experimental study on a deburring method of micro slots of Ti6Al4V tubes with ultra-small-grinding (USG) tool.

The micro structures milled on Ti6Al4V tubes are so narrow that to be damaged in deburring by conventional methods. In this study, a deburring method for the top burrs on micro slots of Ti6Al4V tubes was proposed. The ultra-small-grinding (USG) tool was applied to grind the roots of top burrs for deburring. The method can replace the big milling burrs with the small grinding burrs. A prediction model of the grinding burr size considering workpiece shape and tool deflection was proposed. The ideas of volume balance and energy balance were applied in modeling. Corresponding experiments were conducted with ultra-small-grinding (USG) tools with diameters ~ 100 µm. The effectiveness of the method and the prediction model were proved by the experimental results. The varieties of the grinding burrs in different deburring parameters were studied. The size of grinding burr increase with the increasing of the feeding velocity. The proper deburring parameters are 1–3 mm/min feeding velocity and 10 µm axial cutting depth. The morphologies of the grinding burrs can be divided into four types, which are continuous stacked tiny burr, continuous stacked small burr, discontinuous stacked modern burr, and discontinuous single big burr. The grinding burrs along the side of micro slot can be divided into four kinds of contours, which are smooth contour, rippled contour, wavy contour, and surge contour. The grinding burrs along the sides of micro slots were stacked in the form of laminated tiles, and some strip structures were on the surface of the grinding burrs. [ABSTRACT FROM AUTHOR]