Study on Simulation of Turning Burr Formation Based on Finite Element Method

Abstract

Abstract: According to the relative motion of tool and workpiece, a new mechanical-thermal coupling finite element model of turning burr formation was established. It adopted supporting plate method to eliminate the influence of workpiece deformation which remained on the workpiece side. Operational efficiency improved greatly under this model. Based on the analysis of simulation results, it is discovered that there are both bending deflection and partly cutting occurred on cutting layer material. AISI1045 steel turning experiment was conducted, it is found that the results of simulation are close to the experimental. The model provides an effective way for analyzing the cutting heat, cutting force, workpiece deformation, stress flow and so on in the process of burr formation.

Key words: turning burr, supporting plate method, finite element model, mechanical-thermal coupling

CLC Number:

TG501.1

Zhu Yunming, Huang Jingui, Wang Guicheng, Chen Yun. Study on Simulation of Turning Burr Formation Based on Finite Element Method[J]. Journal of System Simulation, 2015, 27(5): 1120-1126.

References

[1] Toropov Andrey, Ko Sung-Lim, Kim Byung-Kwon.Experimental Study of Burrs Formed in Feed Direction when Turning Aluminum Alloy Al6061-T6[J]. International Journal of Machine Tools & Manufacture (S0890-6955), 2005, 45(9): 1015-1022.
[2] Lauderbaugh L Ken.Analysis of the Effects of Process Parameters on Exit Burrs in Drilling Using a Combined Simulation and Experimental Approach[J]. Journal of Materials Processing Technology (S0924-0136), 2009, 209(4): 1909-1919.
[3] Heisel U, Schaal M, Wolf G.Burr Formation in Milling with Minimum Quantity Lubrication[J]. Prod. Eng. Res. Devel (S1174-0008), 2009, 3(1): 23-30.
[4] Saptaji Kushendarsyah, Subbiah Sathyan, Dhupia Jaspreet Singh.Effect of Side Edge Angle and Effective Rake Angle on Top Burrs in Micro-Milling[J]. Precision Engineering (S0141-6359), 2012, 36(3): 444-450.
[5] Gillespie L K, Blotter P T.The Formation and Properties of Machining Burrs[J]. ASME J Eng Ind (S0268-3768), 1976, 98(1): 66-74.
[6] Sung-Lim Ko, Dornfeld D A.A Study on Burr Formation Mechanism[J]. Trans ASME J, Eng Mater Technol (S1573-4803), 1991, 113(1): 75-87.
[7] Sung-Lim Ko, Dornfeld D A.Analysis and modelling of burr formation and breakout in metal[C]// Proceedings, Symposium on Mechanics of Deburring and Surface Finishing Processes at 1989 ASME Winter Annual Meeting (R J Stango, P R Fitzpatrick). New York, USA: ASME, 1989, 38: 79-92.
[8] Chern G L.Study on Mechanisms of Burr Formation and Edge Breakout Near the Exit of Orthogonal Cutting[J]. J Mater Process Technol (S0924-0136), 2006, 176(1-3): 152-157.
[9] 王贵成, 朱云明, 张春晔. 两侧方向毛刺形成的数学模型[J]. 兵工学报, 2003, 24(4): 513-515.
[10] Wang G C, Zhang C Y.Cutting-direction burr formation in orthogonal precision cutting[J]. Trans Nanjing Univ Aeronautics Astronautics (S1005-1120), 2001, 18(2): 194-199.
[11] Stéphane Segonds, Jacques Masounave, Victor Songmene, et al. A Simple Analytical Model for Burr Type Prediction in Drilling of Ductile Materials[J]. Journal of Materials Processing Technology (S0924-0136), 2013, 213(6): 971-977.
[12] Ravi Lekkala, Vivek Bajpai, Ramesh K Singh, et al. Characterization and Modeling of Burr Formation in Micro-End Milling[J]. Precision Engineering (S0141-6359), 2011, 35(4): 625-637.
[13] Andrey Toropov, Sung-Lim Ko.A Model of Burr Formation in the Feed Direction in Turning[J]. International Journal of Machine Tools & Manufacture (S0890-6955), 2006, 46(15): 1913-1920.
[14] I W Park, D A Dornfeld.A Study on Burr Formation Processes Using the Finite Element Method-Part I[J]. Trans ASME, J Eng Mater Technol (S1433-3015), 2000, 122(2): 221-228.
[15] W J Deng, W Xia, Y Tang.Finite Element Simulation for Burr Formation Near the Exit of Orthogonal Cutting[J]. Int J Adv Manuf Technol (S0268-3768), 2009, 43(9-10): 1035-1045.
[16] 朱云明, 王贵成, 王志, 等. 金属切削毛刺形成的有限元模型及其机理分析[J]. 应用基础与工程科学学报, 2005, 13(2): 180-184.
[17] Yu Long, Changsheng Guo.Finite Element Modeling of Burr Formation in Orthogonal Cutting[J]. Machining Science and Technology (S1091-0344), 2012, 16(3): 321-336.
[18] Deng WJ, Xia W, Lu LS, Tang Y. Finite Element Modeling of Burr Formation in Metal Cutting With a Backup Material [J]. Adv Mater Res (S1022-6680), 2007, 24-25(1): 71-76.
[19] 曲海军, 王贵成, 朱云明. 车削进给方向毛刺的有限元分析[J]. 机械科学与技术, 2011, 30(9): 1485-1489.
[20] 王贵成. 切削运动—刀具切削刃毛刺分类新体系及其应用[J]. 应用基础与工程科学学报, 1995, 3(3): 295-301.
[21] 李彬, 邓建新, 段振兴, 等. 考虑材料与摩擦特性的切削温度场仿真与试验[J]. 机械工程学报, 2010, 46(21): 106-111.
[22] Molinari A, Musquar C.Adiabatic shear banding in high speed machining of Ti-6Al-4V: Experiments and modeling[J]. International Journal of Plasticity (S0749-6419), 2002, 18(4): 443-459.