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DESIRED WORKING ZONE Fig 15 Contour plot of circularity vs. feed rate and spindle speed EFFECT OF CUTTING VARIABLES ON EXIT BURR Drilling process creates burr both on entry and exit surface. In multi-layer metal stacks, the burr at the exit surface of Ti is a major problem that necessitates disassembly of the stack, deburring and re-assembly [10]. The formation of burrs at the entry and exit region is similar to the formation of chips. When the work material on the exit side becomes too weak to support the thrust force, partially formed chips bend in the direction of the cutting velocity at the end of the cut leading to the formation of burr at that point.

10] Rui Li, Parag Hegde, and Albert J. Shih, (2007) ‘High-throughput drilling of titanium alloys’, International Journal of Machine Tools & Manufacture, Vol. 47, pp. 63-74. [11] Ramulu ,M,. Branson,T. ( 2001) ‘A study on the drilling of composite and titanium stacks’, Composite Structures, Vol. 54, pp. 67-77. [12] Ramulu,M , Rao,P,N and Kao,H (2002) ‘Drilling of (Al2O3)p/6061 metal matrix composites’, Journal of Materials Processing Technology, Vol. 124, pp. 244-254. [13] Ribeiro,M,V,. Moreira,M,R,V and Ferreira,J,R (2003) ‘Optimization of titanium alloy (6Al–4V) machining’, Journal of Materials Processing Technology, Vol.

1007/s00170-006-0811-0. [39]. R. S. Khamba, Taguchi Technique for Modeling Material Removal Rate in Ultrasonic Machining of Titanium, Materials Science and Engineering A, Vol. 365-369. (2007) [40]. 327-334. (2005) [41]. Y. C. Venkatesh, S. Sharif, S. Elting and A. Abdullah, Application of Response Surface Methodology in Describing the Performance of Coated Carbide Tools When Turning AISI 1045 Steel, Journal of Materials Processing Technology, Vol. 46-58. (2004) [42]. P. 1007/s00170-006-0429-2. (2005) [43].

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