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TECHNICAL PAPERS

A Study of Burr Formation Processes Using the Finite Element Method: Part I

[+] Author and Article Information
I. W. Park

Integrated Surgical Systems, Inc., 1850 Research Park Dr., Davis, CA 95616

D. A. Dornfeld

Department of Mechanical Engineering, University of California, Berkeley, Berkeley, CA 94270-1740

J. Eng. Mater. Technol 122(2), 221-228 (Dec 31, 1999) (8 pages) doi:10.1115/1.482791 History: Received June 26, 1998; Revised December 31, 1999
Copyright © 2000 by ASME
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References

Gillespie,  L. K., and Blotter,  P. T., 1976, “The Formation and Properties of Machining Burrs,” ASME J. Eng. Ind., 98, Feb., pp. 64–74.
Iwata,  K., Ueda,  K., and Okuda,  K., 1982, “Study of Mechanism of Burrs Formation in Cutting Based on Direct SEM Observation,” J. Japan Society of Precision Engineering, 48-4, pp. 510–515.
Ko,  S. L., and Dornfeld,  D. A., 1991, “A study on Burr Formation Mechanism,” ASME J. Eng. Ind., 98, No. 1, pp. 66–74.
Chern, G. L., 1993, “Analysis of Burr Formation and Breakout in Metal Cutting,” Ph.D. Thesis, University of California, Mechanical Engineering Department, pp. 25–42.
Chern,  G. L., and Dornfeld,  D. A., 1996, “Burr/Breakout Development and Experimental Verification,” ASME J. Eng. Mater. Technol., 118-2, pp. 201–206.
Pekelharing,  A. J., 1978, “The Exit Failure in Interrupted Cutting,” CIRP Ann., 27, pp. 5–10.
Klamecki, B. E., 1973, “Incipient Chip Formation in Metal Cutting—Three Dimension Finite Element Analysis,” Ph.D. dissertation, Univ. of Illinois, Urbana-Champaign.
Usui,  E.Shirakashi,  T., 1982, “Mechanics of Machining-From ‘Descriptive ’ to ‘Predictive’ Theory,” On the Art of Cutting Metals—75 Years Later, ASME Publication PED, 7, pp. 13–35.
Strenkowski,  J. S., and Carroll,  J. T., 1985, “A Finite Element Model of Orthogonal Metal Cutting,” ASME J. Eng. Ind., 107, pp. 349–354.
Park, I. W., Lee, S. H., and Dornfeld, D. A., 1994, “Modeling of Burr Formation Processes in Orthogonal Cutting by the Finite Element Method,” ESRC Report No. 93–34, Univ. of California, Berkeley, Dec.
Komvopoulos,  K., and Erpenbeck,  S. A., 1991, “Finite Element Modeling of Orthogonal Metal Cutting,” ASME J. Eng. Ind., 113, No. 3, pp. 253–273.
Hibbitt, Karlsson, and Sorenson, Inc., 1988, ABAQUS/Explicit User’s Manuals, Version 5.3, Providence, RI.
Wright,  P. K., 1982, “Predicting the Shear Plane Angle in Machining from Workmaterial Strain-Hardening Characteristics,” ASME J. Eng. Ind., 104, No. 3, pp. 285–292.
Lin,  Z. C., and Lin,  S. Y., 1992, “A Coupled Finite Element Model of Thermo-Elastic-Plastic Large Deformation for Orthogonal Cutting,” ASME J. Eng. Mater. Technol., 114, pp. 218–226.
Cockcroft,  M. G., and Latham,  D. J., 1968, “Ductility and Workability of Metals,” J. Inst. Met., 96, pp. 33–39.
ASME Research Committee on Metal Cutting Data and Bibliography, 1952, Manual on Cutting of Metals with Single-Point Tools, The American Society of Mechanical Engineering.
Stiles, T. A., 1985, “A Scanning Electron Microscope (SEM) Machining Substage for Metal Cutting Observation and Acoustic Emission Analysis,” MS thesis, Univ. of California, Berkeley, Department of Mechanical Engineering.
Barsom, J. M., and Rolfe, S. T., 1987, Fracture & Fatigue Control in Structures, Prentice-Hall Inc., New Jersey.

Figures

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A finite element model of burr formation
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Stress-strain curves of the ductile failure model
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Metal-cutting simulation procedure by ductile failure model
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Mesh deformation in steady-state cutting
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Constraint for allowable machined surface finish
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Element groups of a FEM model and cutting path in thick burr simulation
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Flowchart of metal cutting and burr formation simulation
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Progressive change of geometry in thick burr simulation
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Progressive change of geometry in thin burr simulation
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Formation of positive shear on the workpiece edge
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Development of positive shear on the workpiece edge in burr formation
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Negative deformation zone and SEM micrograph of a thin burr
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Negative deformation zone and SEM micrograph of a thick burr

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