Automated drilling and riveting are pivotal for enhancing aircraft assembly quality and efficiency. However, burr formation during robotic drilling of aircraft panels remains a critical challenge, impacting component longevity and safety. This study systematically analyzes how clamping force, spindle speed, and feed rate influence burr generation. Finite element modeling identified an optimal clamping force threshold to suppress interlayer burrs. Further simulations quantified the effects of machining parameters on burr formation. Through response surface methodology experiments, parameter interactions affecting burr height are determined and the process is optimized: 462 N clamping force, 1239 r/min spindle speed, and 124 mm/min feed rate minimized burrs. This approach provides theoretical insights into burr dynamics and practical guidelines for rapid parameter optimization, enhancing aircraft panel reliability and sustainable manufacturing.
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