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TECHNICAL PAPERS

A Study of Burr Formation Processes Using the Finite Element Method: Part II—The Influences of Exit Angle, Rake Angle, and Backup Material on Burr Formation Processes

[+] 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), 229-237 (Dec 31, 1999) (9 pages) doi:10.1115/1.482792 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, pp. 64–74.
Ko,  S. L., and Dornfeld,  D. A., 1991, “A study on Burr Formation Mechanism,” ASME J. Eng. Ind., 112, 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,” Ann. CIRP, 27, pp. 5–10.
Iwata,  K., Ueda,  K., and Okuda,  K., 1982, “Study of Mechanism of Burrs Formation in Cutting Based on Direct SEM Observation,” JSPE, 48-4, pp. 510–515.
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.
Park, I. W. and Dornfeld, D. A., 1995, “A Study of Burr Formation Processes Using the Finite Element Method Part I,” ESRC Report No. 95-32, Univ. of California, Berkeley, Sept., 1995.
Hibbitt, Karlsson, and Sorenson, Inc., 1988 ABAQUS/Explicit User’s Manuals, Version 5.3, Providence, RI.
Hills D. A., and Novell D., 1994, Mechanics of Fretting Fatigue, Kluwer Academic Publisher, London.
Barsom, J. M., and Rolfe, S. T., 1987, Fracture & Fatigue Control in Structures, Prentice-Hall, Englewood Cliffs, NJ.
Rowe,  G. W., and Spick,  P. T., 1967, “A New Approach to Determination of the Shear Plane Angle in Machining,” ASME J. Eng. Ind., 89, pp. 530–538.
Wright,  P. K., 1982, “Predicting the Shear Plane Angle in Machining from Workmaterial Strain-Hardening Characteristics,” ASME J. Eng. Ind., 104, pp. 285–292.
Gillespie,  L. K., 1975, “Hand Deburring Precision Miniature Parts,” Precis. Eng., 1, No. 4, pp. 189–198.
Gillespie, L. K., 1975, “Burrs produced by Drilling,” Bendix Corporation, Unclassified Topical Report BDX-613-1248, Dec., 1975.

Figures

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Finite element models of 60, 80, 90, 100, and 120 degree exit angles
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Finite element models of 5 and 20 degree rake angles
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Finite element models of backup materials
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Equivalent stress contour of 60 degree exit angle
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Shear stress contour of 60 degree exit angle
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Edge breakout of 60 degree exit angle
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Equivalent stress contour of 80 degree exit angle
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Shear stress contour of 80 degree exit angle
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Edge breakout of 80 degree exit angle
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Equivalent stress contour of 90 degree exit angle
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Shear stress contour of 90 degree exit angle
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Formation of negative deformation zone in burr formation
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Shear stress contours of 100 and 120 degree exit angle
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Equivalent stress contours of 100 and 120 degree exit angle
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Final burr configuration of 100 and 120 degree exit angles
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Pekelharing’s tool life experiment results in orthogonal cutting, from 5
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Development of negative shear stress closest to the tool edge
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Location of burr initiation of 20 degree rake angle
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Location of burr initiation of 5 degree rake angle
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Equivalent stress contour with 10 mm backup material
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Normal stress contour in y-direction with 5 mm backup material
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Influence of backup material partially supporting workpiece

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