Burr Control using Modified Tool Geometry: A 3D FEM Approach
This work presents finite element based 3D-machining simulations. Cutting simulations for orthogonal machining case for AA2024-T351 are performed. Quantitative predictions of negative burr lengths on machined workpiece-end, alongwith specific chip shape formation has been made. Numerically acquired chip geometrical shape and results of machining forces are compared with the associated experimental results from literature. Onwards, machining simulations with a modified cutting tool geometry have been reproduced. It has been found that convex shape modified tool geometry helps to restrict early formation of crack in front of tool and control the material deformation in cutting direction. This helps reducing material flow towards edges and formation of exit burr and edge breakout.