Prediction of thickness and height of burr based on burr formation mechanisms in end milling

Edge imperfections are often introduced on workpieces due to plastic deformation during machining. These imperfections are known as burrs. Since the deburring operation is costly, the control of burr formation is a research topic of great significance for industrial applications. This study introduces a system that focuses on the prediction of burr dimensions and positions in the end milling process as a preventive measurement method. This system is based on burr formation models, analytical cutting force model, and experimental validation. Two kinds of burr models were used, rollover burr and Poisson burr. The orthogonal and oblique cutting were also used in the system based on different positions. A Window based program is developed to illustrate the machining process upon PC-based NC simulator that consisted of geometric simulator and physical simulator. The geometric simulator consists of the feature identification and the cutting condition identification. The physical simulator contains cutting force model that used to calculate the force in feed direction that leaded burr to form. The propose system was compared with experimental in difference workpiece materials for validation. It was verified that top burr and exit burr in up milling and down milling can be predicted. Both the predicted and experimental results were found to agree in most of the cutting conditions.