Analysis of the Deburring Efficiency of EN-AW 7075 Aluminum Alloy Parts with Complex Geometric Shapes Considering the Tool Path Strategy During Multi-Axis Brushing

The paper presents the results of an analysis of the effect of brushing on the edge condition of workpieces with complex geometric shapes, formed during milling, on a five-axis DMU 100 monoBLOCK machining center. A set of EN-AW 7075 aluminum alloy specimens with curvilinear edges requiring multi-axis machining was prepared. The change of edge condition after the milling process was realized using Xebec tools with flexible ceramic fibers. The effects of brush fiber type and parameters related to tool design were analyzed. Different brushing strategies were employed on the five-axis machining center. It was shown that, for curvilinear edges, there were different effects for concave and convex edges depending on the employed tool strategy, including the type of tool, its configuration, and its orientation towards the workpiece. For a lead angle of β = 0°, the machined edge was characterized by variable chamfer widths, in spite of maintaining other machining parameters constant. The use of a lead angle β > 0 produced a stable edge with repeatable characteristics. The range of fiber interaction increased with increasing the lead angle and fiber working length.