FINITE ELEMENT MODELING OF BURR FORMATION IN ORTHOGONAL CUTTING

A finite element model for orthogonal cutting is developed and applied to simulate burr formation. Three typical workpiece materials were investigated. The simulation results reveal the entire burr formation process. The simulation produces either positive or negative burrs depending on the material properties, which is in agreement with experimental observations from literature. Both shear and normal stress failures are presented for negative burr formation while only shear stress failure leads to positive burr formation. The FE modeling results confirm that material property is the dominant factor in controlling burr formation.