Simulation Model and Mechanism of Burr Formation

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.