Research On Burr Formation Mechanism In Metal Cutting With A Backup Material

Burr formation, resulting from the plastic deformation of the workpieces,is a normal phenomenon in metal cutting process. It affects the machining quality and machining efficiency directly. And it has become a major challenge of precision/ultra-precision manufacturing and automatic machining. Metal cutting with a backup material, which was proposed in the last century, is an effective burr control technology. However, its mechanism, influence factors and optimal parameters were still rarely involved. Thus, it is necessary to conduct sufficient researches and make clear its scope of application and optimal routes. The main research contents are as follow:(1) Based on DEFORM 2D, a thermomechanical finite element model was established to make comprehensible the deformation behavior and burr control mechanism of metal cutting with a backup material. The influences of backup material parameters such as the height, thickness, shapes and backup material types on the value of effective stress, cutting force and cutting temperature had been fully studied.(2) With the combination of experimental researches and finite element simulations, an experimental platform and efficient simulation model were set up. The effects of backup material parameters on burr height and burr root thickness were studied. Through this study, the optimal backup material parameters were obtained.(3) By comparing the experimental results with the simulation results, an accurate and efficient computing finite element model aimed at providing guidance for practical manufacturing was built up.Results show that all of the backup material parameters such as backup material height, thickness, shape, type of backup material and fixed height have significant impats on burr morphology and burr size. And cutting with a backup material is an excellent choice for burr minimization. Effective burr control can be achieved while selecting the appropriate backup material parameters. Therefore, the technique will have a wide range of application prospects. And its application can save the time and cost of deburring and significantly improve the production efficiency, which will bring remarkable economical and societal benefits.