Finite Element Modelling of burr formation in metal cutting

The paper presents a two-dimensional FEM model of burr formation in metal cutting. Abaqus/Explicit software was used for the build of the model. The workpiece geometry, the tool and the cutting parameters were modelled. Physical properties and the method of deformation and fracture of the workpiece material is described using Johnson Cook's constitutive law and the ductile damage criterion. The simulation of the edge formation process during orthogonal cutting was carried out for different depths of cut and cutting speeds. The results of these simulations allowed the verification of the FEM model. The components of the resultant cutting force measured during the actual cutting process with the values of these forces determined based on FEM simulation of this process were compared. The geometry of burrs formed during the actual and simulated the edge forming process was assessed. The analysis showed that the FEM model built enabled a correct prediction of the shape of the workpiece edge and the estimation of geometric features of the edge.