FE simulation and experimental verification of side-flow and burr formation in machining of oxygen-free copper

This article considers the influence of cutting data on burr formation when machining oxygen-free copper in a longitudinal turning operation. Burr formation and side-flow frequently occur in a cutting process, resulting in highly undesirable poor surface integrity and reduced dimensional accuracy of the machined components. Finite Element (FE) simulations of a cutting process were used to simulate radial burr formation for variable cutting depth, feed and major cutting edge angle. The results from FE simulations are compared with the experiments of longitudinal turning. Decrease of depth of cut and major cutting edge angle result in reduced burr formation. Additionally, high speed filming performed during the machining revealed a five-stage cycle of burr formation. (C) 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the 51st CIRP Conference on Manufacturing Systems.