Numerical Modeling the Effects of Chamfer and Hone Cutting Edge Geometries on Burr Formation

A finite element based numerical model to simulate orthogonal machining process and associated burr formation process has been developed in the presented work. To incorporate simultaneous effects of mechanical and thermal loadings in high speed machining processes, Johnson and Cook`s thermo-visco-plastic flow stress model has been adopted in the conceived numerical model. A coupled damage-fracture energy approach has been used to observe damage evolution in workpiece and to serve as chip separation criterion. Simulation results concerning chip morphology, nodal temperatures, cutting forces and end (exit) burr have been recorded. Model has been validated by comparing chip morphology and cutting force results with experimental findings in the published literature. Effects of cutting edge geometries [Hone and Chamfer (T-land)] on burr formation have been investigated thoroughly and discussed in length. To propose optimum tool edge geometries for reduced burr formation in machining of an aerospace grade aluminum alloy AA2024, numerical analyses considering multiple combinations of cutting speed (two variations), feed (two variations) and tool edge geometries [Hone edge (two variations), Chamfer edge (four variations)] have been performed. For chamfer cutting edge, the “chamfer length” has been identified as the most influential macro geometrical parameter in enhancing the burr formation. Conversely, “chamfer angle” variation has been found least effecting the burr generation phenomenon.