Study On Formation Model And Control Method Of Burrs In Micro-milling

Micro-cutting technology is built based on traditional mechanical cutting technology,integrating numbers of high technology, which is suitable for machining parts and assemblies in small sizes. Micro-cutting technology becomes the important research area of many researchers due to its special advantages in process of metal parts with complex shapes, high strength, micro size and multi-scale. Micro burrs is one of the main problems in micro cutting, and it is very difficult to remove these burrs. So it has important theoretical significance and practical value to do research on burr formation and control technology.Finite element method software ABAQUS was used to simulate the formation of cutting-feed direction burrs, factors that affect top burr formation in micro drilling slot were analyzed by experiment, also what kind of effects caused by cutting edge radius on burr sizes were analyzed. Micro cutting technology, burr formation theory and burrs classification were detail discussed at the same time. Some effective technologies and solutions of burr control in micro cutting were raised at the end of this paper. The main contents and innovations of this paper are as follows:(1) Systematic statement of the research status of micro cutting technology and mechanism, micro burrs formation and micro cutting simulation. Pointing out the main problems involved. Built 2D cutting model by ABAQUS/Explicit, explained the formation mechanism of burr through orthogonal method.(2) According to the simulation results, analyzed the effects of tool rake angle, cutting speed and cutting depth on cutting-feed direction burrs, gained a set of cutting parameters which can minimize burr size.(3) Through micro milling groove experiment, performed a deep research on the effect of cutting parameters(cutting speed, main axis spindle speed, feeding speed) on top burr formation. Summarized the regular and reasons of different factors. Used three tools with different abrasion degree to analyze the effect of cutting edge radius on top burrs. These researches provide theory reference for cutting parameters choosing in micro milling.(4) Raised some cutting methods burr control technology which is suitable for real production to accomplish little or no burrs during machining according to micro milling experiment and the characteristic of micro cutting. Provide theory reference for micro cutting production.This research work is a part of National Natural Science Foundation of China project(No.51075192).The research results of this paper will enrich and expand the theory of burr formation and control technology in micro-milling. In the long term,it has a certain theoretical and practical value.