Experimental and Numerical Investigation of Burr Formation in Intermittent Turning of AISI 4140

Burr formation is a problematic aspect in the machining of ductile metals. Understanding the formation mechanism and being able to model the plastic workpiece behavior during tool exits is key to burr minimization. A 3D finite element model is used to simulate burr formation during the exit phase of intermittent turning of AISI 4140, using a nose radiused insert. The model is validated by experimental results of dynamic force measurement and analysis of the burrs produced. The exit burr height obtained via simulation closely corresponds to the experimentally obtained values.