Hai Jun Qu

Formation and Simulation of Cutting-Direction Burr in Orthogonal Cutting

The cutting-direction burr is one of the important factors that influence the edge quality and performance of precision parts. The cutting-direction burr formation process is simulated with DeformTH3D. The mechanism of cutting-direction burr formation is analyzed in terms of the results of the simulation. The negative shear zone and initiation negative shear angle are discussed too. Study results show that the deformation of CDE is an important factor affect the cutting direction burrs’ size and shape.

Formation and Simulation of Two-Side Burr in Orthogonal Cutting

The two-side burr is one of the important factors that influence the edge quality and performance of precision parts. The two side-direction burr formation process is simulated with DeformTH3D. The mechanism of two-side burr formation is analyzed in terms of the results of the simulation. Enlarging the tool orthogonal rake and minimizing the depth of cut can reduce the burr size.

Transformation of Cutting Burr/Fracture in High-Speed Machining Al Alloy

The metal cutting burr is one of the factors that influence the edge quality and performance of precision parts.A finite element model has been established to investigate the mechanism of burr formation and limit transformation in high-speed machining 2024Aluminum alloy .The burr/fracture formation process is simulated with elastic-plastic nonlinear element method based on ABAQUS.This paper has investigated the mechanism of burr /fracture formation and the limit transformation condition of cutting-direction burrs and fractures in high-speed machining and the limit transformation condition change with the cutting condition,which lay scientific basis of further research on cutting burrs formation and its minimization and deburring technology.

Formation and Control of Two Side Direction Burr

Based on the orthogonal cutting experiments, the two side direction burrs in metal cutting were studied. In this study, the cutting model of two side direction burr formation and translation is established with plane stress-strain theory. The main laws of formation and change of burr in size and type in orthogonal cutting are revealed, and it is confirmed by experiment results, which first realizes control of the forming and change of the two side direction burr in metal cutting operation.

Formation and Control of Cutting Direction Burr in Machining

In this paper, the forming processes, main effect factors and change law of the cutting direction burr in orthogonal cutting have been studied and related theories are analyzed based on the cutting experiments. The result shows that the forming processes of cutting direction burr consist of normal cutting, flexure deformation of end surface of workpiece, plastic effect, continuous cutting and shear-break separating in orthogonal cutting. And a new phenomenon was found that cutting direction burr is formed with the shear-break separation of the chip and workpiece machined surfaces. In addition, the size of cutting-direction burr varies with workpiece materials, cutting parameters and geometric parameters of cutting tool. The study may be important science and practical value in order to control and reduce cutting burr in precision machining.

Formation of Cutting Direction Burr/Fracture in Orthogonal Cutting

Cutting direction burr/fracture is one of the important factors that influence the edge quality and performance of precision parts. A finite element model based on material failure mode is developed in this study to simulate the burr /fracture forming process. According to workpiece materials deformation and mechanical properties from the simulation results, the cutting direction burr/fracture formation process is analyzed. The cutting direction burr forms when there is a crack in the area near the tool tip and grow along the principal shear zone, the cutting direction fracture forms as the crack grow along negative zone.

Analysis of the Feed Direction Burr in Turning Based on FEM

A finite element model was developed for simulation of feed direction burr formation process in turning. Based on a series of stress and strain contours the progressive change of geometry at the edge of workpiece edge from simulation, a turning feed direction burr formation mechanism is proposed and divided into four stages: normal cutting stage, deformation of workpiece edge stage, continues cutting stage and final developed stage. The removal of the remaining part of allowance takes place close to the tool tip as the material has sufficient rigidity to allow cutting only in this area in final developed stage and secondary burr will be formed; primary burr will be formed in final developed stage if the remaining material has no rigidity to allow cutting continually in final developed stage. The burr size and burr shapes form simulation results are consistent with the experimental results. Finite element model generated here provided a numerical analysis method to solve the prediction of burr formation and physical insight into the fundamental burr formation mechanism.

Influences of End Surface Angle of Workpiece on Burr Formation in High Speed Machining

The end surface angle of workpece is one of key factors that affect burr sizes and shapes. In this paper, the burr formation process of different end surface angle is simulated with elastic plastic nonlinear element method based on ABAQUS. The influence of end surface angle of workpiece on burr formation processes in high-speed machining 2024 Aluminum alloy is analyzed. The influence of end surface angle on burr sizes and shapes is studied based on equivalent shear strain and negative shear angle. The results have investigated the mechanisms of burr formation fundamentally, which is the basis of burr minimization.

Forming and Control of Feed-Direction Burr in Drilling

A forming model of the feed-direction burr for drilling process is made in this paper. The feed-direction burr formation is studied by experiment. The related theories are analyzed. The influence factors of the feed-direction burrs are pointed out. Furthermore, a certain number of measures to prevent and decrease the burr in drilling process are advanced.

The Effect of Shear Strain on Transformation between Burr and Negative Burr

In most machining operations undersirable burr or negative burr is created at workpiece edges. The burr/negative burr formation mechanism is analyzed based on shear strain which is obtained from simulation results of the finite element model of burr/negative burr forming process. To varify the simulation results, experiments are conducted. We observered that there exists a critical value of shear strain for burr/negative burr transformation. Burr or negative burr, which to be formed at workpiece edges can be controlled by adjusting the cutting conditions or tool geometric parameters. Edge quality of workpiece can be controlled by converting burr or negative burr forming.