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Analytical modeling of Poisson burr formation in the machining of Al6061 with interface constraint

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Abstract

During the cutting process, unnecessary burrs frequently emerge along the cutting edge. To suppress the burrs generated in the process, an effective method is to provide interface constraint next to the workpiece, such as ice fixation machining. Although experimental evidence demonstrates that interface constraint effectively inhibits burrs, the understanding of its inhibitory mechanism remains limited. In this paper, the suppression mechanism of interface constraint on Poisson burr is analyzed, and an analytical model for predicting the size of Poisson burr with interface constraint is established. The model can predict the height and thickness of the Poisson burr, and it is verified by the finite element method and experiment. The inhibition effects of interface constraint on the Poisson burr under different workpiece strengths, cutting depths, cutting widths, tool rake angles, and constraint strengths are compared. The results show that interface constraint effectively reduces Poisson burr size, and the prediction model accurately describes both the size and shape of the Poisson burr. Workpiece material, tool rake angle, cutting depth, and constraint strength all significantly impact the size of the Poisson burr. Consequently, this paper offers enhanced insight into the mechanism of suppressing Poisson burrs by adding interface constraint and provides a theoretical reference for optimizing machining parameters.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Abbreviations

A :

the yield strength under quasi-static conditions

a :

the heat diffusivity

a c :

the cutting depth

a 0, a 1, a 2 :

the constitutive coefficient of ice

α 0 :

the rake angle

B :

the material strain hardening parameter

b :

the cutting width

β :

the friction angle

C :

the material strain rate strengthening parameter

D 1, D 2, D 3, D 4, D 5 :

equation fitting coefficients

d :

the depth of the elastic-plastic boundary

δ :

the angle between the force and the plane

E T :

the energy consumed by plastic deformation of the material

E s :

the total energy of shear action

ε(y, z):

the plastic strain in the y-z plane

ε :

the strain of the material

ε E :

the strain of elastic-plastic boundary

ε S :

the plastic strain of the machined surface

ε p :

the material equivalent plastic strain

\(\dot{\varepsilon}\) :

the material equivalent plastic strain rate

\(\dot{\varepsilon_0}\) :

the material reference strain rate

E I :

the energy consumed by the interface constraint

F r :

the cutting force

f s :

the friction coefficient

φ :

the shear angle

γ s :

the shear strain on the shear surface

H :

the burr height

J 1, J 2 :

the plastic strain distribution coefficient

K :

the exponential constitutive coefficient

K 0 :

modified Bessel function

m :

the material thermal softening parameter

μ :

Poisson’s ratio of the workpiece material

n :

the material strain hardening index

p :

the hydrostatic stress

q :

the power of the heat source

r 0 :

the radius of the circle

σ :

the flow stress of the material

σ r :

the radial stress component

σ θ :

the circumferential stress component

σ s ′ :

the yield strength of the support material

σ x :

the stress component in the x-axis direction

σ s :

the yield stress of the workpiece material

σ q :

the octahedron shear stress

T :

the thickness of the burr

t melt :

the reference temperature

t 0 :

the material melting point

t j :

the temperature change at point j

τ :

the shear stress

τ rθ :

the circumferential shear stress in the y-z plane

τ xr :

the radial shear stress in the y-z plane

τ θx :

the shear stress perpendicular to the y-z plane

θ :

the angle between the radial stress component and the z-axis

ϑ :

the heat conductivity

v :

cutting speed of the tool

Y, Z :

the positions of point j

η :

the stress triaxial degree

z c :

the projection length of the heat source on the y-axis

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Funding

The authors gratefully acknowledge the financial support from the National Natural Science Foundation of China (No. U20B2033, 51975093), the Natural Science Foundation of Liaoning (No. 2020-YQ-09), and the Changjiang Scholar Program of the Chinese Ministry of Education (No. Q2021053, T2017030).

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Authors and Affiliations

  1. State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, Dalian, 116024, China

    Pengchao Li, Chengxin Wang, Lingqi Zeng, Haibo Liu & Yongqing Wang

Authors
  1. Pengchao Li
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  2. Chengxin Wang
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  3. Lingqi Zeng
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  4. Haibo Liu
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  5. Yongqing Wang
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Contributions

Pengchao Li and Haibo Liu contributed to the establishment of burr analytical model under interface constraint. Chengxin Wang and Yongqing Wang contributed to the finite element simulation. Lingqi Zeng contributed to the data processing.

Corresponding author

Correspondence to Yongqing Wang.

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Li, P., Wang, C., Zeng, L. et al. Analytical modeling of Poisson burr formation in the machining of Al6061 with interface constraint. Int J Adv Manuf Technol 129, 353–374 (2023). https://doi.org/10.1007/s00170-023-12068-8

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  • DOI: https://doi.org/10.1007/s00170-023-12068-8

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