A study of burr formation processes using the finite element method: Part I

A finite element model of orthogonal metal cutting including burr formation is presented. A metal-cutting simulation procedure based on a ductile fail ure criterion is proposed for the purpose of better understanding the burr formation mechanism and obtaining a quantitative analysis of burrs using th e finite element method. In this study, the four stages of burr formation, i.e., initiation, initial development, pivoting point, and final developmen t stages, are investigated based on the stress and strain contours with the progressive change of geometry at the edge of the workpiece. Also, the cha racteristics of thick and thin burrs are clarified along with the negative deformation zone formed in front of the tool edge in the final development stage. [S0094-4289(00)00702-7].