Modelled phenomenon of burr formation during machining

Abstract

A model of burr formation on the edge of the workpiece in the course of machining is presented. The material being machined, the cutting tool and the machining parameters were modelled. Material properties and type of its deformations have been modelled with the use of a constitutive Johnson - Cook model. Material damage initiation criteria and associated damage evolution have been modelled with the use of the ductile damage and the Johnson- Cook damage initiation criterion. Simulations of the machining process for different depths of cut were carried out. The real burr formation presented by Hashimura was compared with the modelled one. The influence of the cutting parameters on the form and size of burr has been analysed. Calculations have been realised utilising finite element method with the use of nonlinear analysis in ABAQUS/Explicit environment. Based on simulation results, the assessment of the form and size of burr has been made. Burr height was used to evaluate its size, which was derived according to ISO 13715 standard. The goal was to obtain a model that reliably reflects the behaviour of material during machining, with particular emphasis on supporting the creation of cutting phenomenon of burr formation. The results of simulation and computational analysis confirmed that the model reflects the real behaviour of the material