Prediction of Exit Burr Formation in Orthogonal Micromachining via FE Modeling

Burr formation is inevitable in micromachining, nevertheless, it can be minimized in several ways. Rake angle is one of the most influencing tool geometrical factors affecting the micro-burr formation, especially in orthogonal machining. The present study has been focused on the prediction of exit burr formation in orthogonal micromachining varying the rake angle of the cutting tool. Finite element modeling has been applied to predict the burr formation using Abaqus software. Three different rake angles have been used for the FE modeling those are 0°, − 15°, and − 30°. Machining has been performed on aluminum alloy Al7075. The results of the FE modeling precipitated that the exit burr width was maximum for machining with 0° rake angle followed by − 15° and − 30°. For validation of the FE modeling, experiments have been carried out using uncoated tungsten carbide cutting tool. The rake angle has been varied accordingly and exit burr formation has been measured. The experiments have shown well similarity with the simulated study. It has been observed that the height of the exit burr was maximum for − 15° rake angle. Eventually, the exit burr formation can be minimized using a higher negative rake angle without compromising with specific cutting energy in orthogonal micromachining.