Optimal Design for Drilled Intersecting Holes to Minimize Burr Formation

Drilling aluminum alloy, particularly Al 6061, presents challenges due to the material's characteristics, often leading to costly burr removal processes. Optimizing drilling methods in aluminum is crucial, especially in scenarios involving multiple intersecting holes. This study investigates exit burr formation in such contexts using the Taguchi method, focusing on optimizing critical design parameters like hole diameters, drilling angles, and hole locations to improve drilling efficiency and precision. By thoroughly analyzing and optimizing the burr formation process and employing a FaroArm Scanner for data collection, the study enhances the accuracy and quality of drilling operations, providing significant benefits to precision-demanding sectors. The findings are especially valuable for industries with stringent precision requirements, such as aerospace and automotive manufacturing.