To improve aerostructures assembly processes, aircraft manufacturers want to implement a One-Way Assembly strategy that eliminates the disassembly, cleaning and deburring phases currently required. Implementing this innovative strategy represents major technical challenges, including the management of burr formation at stack interfaces, as they have a negative impact on the assemblies’ fatigue strength. Despite extensive research, the burr formation phenomenon remains poorly understood. This paper presents an interrupted experimental design to investigate the burr formation during the drilling process of Ti-6Al-4V alloy. Analysis of burr geometry and microstructures is complemented by cutting force results for three different drilling tool geometries.
Science Journal 