A numerical insight on machining burr formation: A comprehension to optimization approach

Muhammad Asad, Hassan Ijaz, Muhammad Azhar Ali Khan, Asim Asghar Yaseen, Taha Waqar, Abdul Aziz Afzal

Research output: Contribution to journalArticlepeer-review

2 Citations (Scopus)


An insight into comprehension and optimization of exit burr formation in orthogonal machining case is presented in the work. Formation of exit burr has been simulated using a three dimensional FE based machining model. Variation of "pivot-point"(point of maximum bending stress, appearing at workpiece exit edge) location on workpiece end and its appearance with respect to tool position during cutting process has been correlated with burr formation process. To minimize the burr formation, machining process variables (including speed, feed and tool rake angle) optimization have been realized employing Abaqus® Burr lengths at exit end along workpiece depth of cut (ap) are quantified and optimum machining parameters generating less burrs for dry machining of AA2024 are identified. Simulated results pertaining to chip and cutting forces are fairly matched with related experimental results in the published literature.

Original languageEnglish
Pages (from-to)1792-1799
Number of pages8
JournalMaterials Today: Proceedings
Issue number4
Early online date30 May 2020
Publication statusE-pub ahead of print - 30 May 2020
Externally publishedYes


  • AA2024
  • Chip formation
  • Exit burr
  • Finite element simulation
  • Optimization

ASJC Scopus subject areas

  • Materials Science(all)


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