Search for a new design of deburring tools for intersecting holes with TRIZ

This work describes a process of design improvement of deburring tools for intersecting holes based on the TRIZ approach. Deburring tests with the previous deburring tool prototypes showed surface irregularity on the deburred edges. The irregularity is due to the complex interaction, governed by various parameters, between the cutter head and the three-dimensional burr edge. The major parameters affecting the tool dynamics are identified and contradiction analysis of TRIZ is performed for the problem. Among the several candidate solution principles, "asymmetry" is adopted for the new design. With the new design based on this principle of asymmetry, variations in the rake angle and cutter face exposure are greatly reduced. Tests on aluminum alloy Al6061-T6 specimens showed significantly less surface irregularity. An index of surface irregularity is proposed.