Modeling And Experimental Study On Burr Formation Process In Fly-cutting

Diamond fly-cutting technology has the advantages on broad range ofmaterial machining, fine surface quality, which draws the key attention fromacademia and industry. It can be successfully applied into machiningmicrostructural surfaces such as microlens array and deceleration reflectiongrating. Regard to the special materials processing like KDP crystal, diamondfly-cutting technology plays an indispensible role. However，large burrs will begenerated in machining oxygen-free copper or other plastic materials. It will notonly greatly reduce the size precision but cause troubles in the normal operation.Meanwhile, subsequent deburring process will reduces productivity greatly.Therefore, it is quite meaningful to study the burr formation process, analyze itsaffecting factors and explore the control methods in the fly-cutting.In order to analyze the burr formation process preferably, the machiningmodel of ultra-precision fly-cutting process was established to study the chip forceconditions. The simulation of chip formation process was carried out, and theminimum chip thickness effect was simulated. The burr formation process wassimulated. The burrs in the cutting out direction were classified according todifferent forms, and the form transition condition of which was studied.The circular arc cutting tool was used in the fly-cutting simulation, and twodifferent cases with and without initial burrs were considered. Through thesimulation, the influence of different machining parameters, tool geometry andmounting angles, and installation positions on the formation of first and secondburrs was studied. It can provide the reference for selecting the processingparameters in the future.The simulation results were experimentally verified. The comparison analysisof experimental and simulation results under different machining parameters wasperformed. The optimization experiments for cutting parameters were carried out.The prediction model of burr height in the cutting out direction was established.Then, optimization of machining parameters was implemented and experimentallyverified. The experiments under workpiece superposition method were carried outto study the inhibition mechanism and effect of burrs in the cutting out direction.