Finite element simulation for burr formation near the exit of orthogonal cutting

A coupled thermo-mechanical model of plane-strain orthogonal metal cutting including burr formation is presented using the commercial finite element code. A simulation procedure based on Normalized Cockroft–Latham damage criterion is proposed for the purpose of better understanding the burr formation mechanism and obtaining a quantitative analysis of burrs near the exit of orthogonal cutting. The cutting process is simulated from the transient initial chip formation state to the steady state of cutting, and then to tool exit transient chip flow by incrementally advancing the cutting tool. The predicted burr profile is compared with experimental data and found to be in reasonable agreement. The effect of the tool conditions and cutting conditions on the burr formation process was also investigated.