Experimental Investigation and Modelling of Burr Formation during Orthogonal Cutting of A356+0.5Cu Aluminium Alloy

Abstract

Burr formation during parts manufacturing is a significant problem that companies try to minimise or eliminate. The present work aims to study the burr formation mechanisms in a cast aluminium alloy. Orthogonal cutting tests are performed using different uncut chip thicknesses and tool rake angles. To analyse burr formation mechanisms, the work material state of stress and triaxiality distribution in the chip root was investigated via numerical simulations. Results show that the uncut chip thickness has an effect on burr morphology and burr cumulation while tool rake angle influences burr height on high uncut chip thicknesses.