Conference Paper

Simulation Model and Mechanism of Burr Formation

DOI: 10.1109/WMSO.2008.60 Conference: Modelling, Simulation and Optimization, 2008. WMSO '08. International Workshop on
Source: IEEE Xplore

ABSTRACT Burrs formation is a very complicated process in metal cutting and its formation mechanism has not yet been fully revealed. A finite element model based on material failure mode is proposed in this study to simulate the burr forming process. According to workpiece materials deformation and mechanical properties from the simulation results, burrs formation mechanism is analyzed. To reveal the changes law of burr formation, experiments with different materials and different cutting conditions are carried out on refitted milling machine. Main factors that influence the burr formation process are analyzed. Also, the effectiveness of the FEM is verified through experimental results.

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    ABSTRACT: Two computer models are described that treat the special case of orthogonal cutting. The models are based on the finite element method, which is used to discretize a portion of the workpiece in the vicinity of the cutting tool. From the models, the detailed stress and strain fields in the chip and workpiece, chip geometry and tool forces can be determined.The first model is based on a specially modified version of a large deformation updated Lagrangian code developed at Lawrence Livermore National Laboratory called NIKE2D, which employs an elastic-plastic material model. The second model treats the region in the vicinity of the cutting tool as an Eulerian flow field. Material passing through the field is modeled as viscoplastic. Results obtained from both models show excellent agreement when compared with measured tool forces for slow speed cutting of aluminium 2024-T361.
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