Burr/Breakout Model Development and Experimental Verification

[+] Author and Article Information
Gwo-Lianq Chern

Department of Mechanical Engineering, National Yunlin Institute of Technology, Touliu, Yunlin, Taiwan 640

David A. Dornfeld

Department of Mechanical Engineering, University of California at Berkeley, Berkeley, CA 94720

J. Eng. Mater. Technol 118(2), 201-206 (Apr 01, 1996) (6 pages) doi:10.1115/1.2804887 History: Received March 03, 1994; Revised March 19, 1995; Online November 27, 2007


The mechanisms of burr formation and breakout in orthogonal cutting are analyzed. A burr formation/breakout model for orthogonal cutting is proposed, based on the observation of SEM micro-machining tests. It is found that a negative deformation plane begins to form when the steady-state chip formation stops as the tool approaches the end of the cut. Plastic bending and shearing of the negative deformation plane contributes to the burr formation, while crack propagation along the plane causes the breakout. Simulated orthogonal cutting experiments using copper, Al 2024-T4, and Al 6061-T6 were performed with a modified impact machine to verify the model. The tests showed excellent agreement with the model predictions.

Copyright © 1996 by The American Society of Mechanical Engineers
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