Lorenzo Bettinardi
Finite Element Simulation of drilling in titanium alloy plates: Burr Formation and Structural Implications.
Rel. Marco Gherlone. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Aerospaziale, 2025
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Abstract
Burrs are unwanted material projections formed during machining processes, such as milling, drilling, turning, or grinding, that deviate from the ideal geometry of the workpiece. Their presence has long been recognized as detrimental for both structural integrity and manufacturing efficiency. On a mechanical level, burrs can reduce strength under static and fatigue loading, damage protective coatings, and generate subsurface defects or contamination. Functionally, they interfere with assembly by causing misalignments and increasing surface roughness, while from a production perspective they require costly, labor-intensive, and non-value-added deburring operations. Indeed, deburring may account for 5–30% of the total manufacturing cost, with significant implications for cycle time, manpower, and rejection rates, especially in the case of small and high-precision aerospace components.
The aerospace industry is particularly affected by burr formation, since drilling represents one of its most common processes
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