Research on the burr-free interrupted cutting model of metals

Abstract

In the interrupted cutting of metal parts, burrs are generally produced at the edge of the exit surface, which will seriously affect the use and assembly performance. Adding deburring process is a way to solve the problem of burr, but it will increase the cost of economy and time, and hinder the automation of production line. This study focused on the active burr control technology, which can prevent burr formation during the cutting process. A new burr-free theoretical model was established based on the analysis of burr formation, and it indicated that changing the exit surface angle of the workpiece was the key to realize burr-free interrupted cutting. The finite element method (FEM) was applied to simulate the cutting burr. In the simulation, ten gradients from 30° to 90° were set for the exit surface angle, both the stress plot and the final burr shape were presented in good agreement with the theoretical model. A cutting experiment of aluminum alloy 7075-T651 was carried out and the burr-free interrupted cutting was realized under the guidance of the derived theoretical model. The critical exit surface angle of burr-free state was also verified by the experiment, which was predicted from the theoretical model. This study provided a theoretical and practical basis for solving burr problem in interrupted cutting.