Int J Adv Manuf Technol (2013) 68:1911–1917  

DOI 10.1007/s00170-013-4801-8

Influence of size effect on burr formation in micro cutting

Tao Zhang, Zhanqiang Liu*,  Chonghai Xu

Abstract: Burr is an important character of thesurface quality for machined parts, and it is even more severe in microcutting. Due to the uncut chip thickness and the cutting edge radius at thesame range in micro cutting process, the tool extrudes the workpiece with negativerake angle. The workpiece flows along the direction of minimum resistance, andPoisson burr is formed. Based on the deformation analysis and experiment observationsof micro cutting process, the factor for Poisson burr formation is analyzed. Itis demonstrated that the ratio of the uncut chip thickness to the cutting edgeradius plays an important role on the height of Poisson burr. Increasing theuncut chip thickness or decreasing the cutting edge radius makes the height ofexit burr reduce. A new model of micro exit burr is established in this paper.Due to the size effect of specific cutting energy, the exit burr heightincreases. The minimum exit burr height will be obtained when the ratio ofuncut the chip thickness to the cutting edge radius reaches 1. It is found thatthe curled radius of the exit burr plays an important role on the burr height.

Keywords: Micro cutting. Poisson burr.Exit burr. Size effect

2013-Influence of size effect on burr formation in micro cutting-1.pdf