Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation

In any mechanical cutting operation including micromilling, burr formation is unavoidable due to the plastically deformed materials generated from the cutting and shearing phenomenon. Compared to macro milling, the size ratio between burr and micro-milling profile is extremely large making the remov...

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Main Authors: Mohd Ali Hanafiah, Shaharudin, Ahmad Razlan, Yusoff
Format: Article
Language:English
Published: Malaysian Tribology Society (MYTRIBOS) 2023
Subjects:
Online Access:http://umpir.ump.edu.my/id/eprint/39149/1/Using%20Finite%20Element%20simulation%20to%20investigate%20the%20effect%20of%20cutting.pdf
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author Mohd Ali Hanafiah, Shaharudin
Ahmad Razlan, Yusoff
author_facet Mohd Ali Hanafiah, Shaharudin
Ahmad Razlan, Yusoff
author_sort Mohd Ali Hanafiah, Shaharudin
collection UMP
description In any mechanical cutting operation including micromilling, burr formation is unavoidable due to the plastically deformed materials generated from the cutting and shearing phenomenon. Compared to macro milling, the size ratio between burr and micro-milling profile is extremely large making the removal process extremely challenging. Due to the challenge, this paper presents the investigation of critical factors in burr formation such as tool cutting edge radius, Rc using the finite element (FE) approach. The first part of the investigation consists of the validation of the FE simulation results with the experimental by comparing the generated cutting force, and the second part focused on the virtual experiment on the investigation of tool cutting edge radius to the burr formation on the machined dimple profile. In the simulation of inclined dimple milling, the 3D model of solid carbide (WC) ball end mill (BEM) tool contact with the round Aluminum Alloy 6061-T6 specimen model at 45° inclination angle to form the dimple profile and the characteristic of the burr profile measured directly on the deformed specimen model. Based on the results, it was found the cutting edge radius, directly proportional to the cutting force and significantly influence the burr formation in inclined dimple milling.
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spelling UMPir391492023-11-01T06:14:58Z http://umpir.ump.edu.my/id/eprint/39149/ Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation Mohd Ali Hanafiah, Shaharudin Ahmad Razlan, Yusoff TA Engineering (General). Civil engineering (General) TS Manufactures In any mechanical cutting operation including micromilling, burr formation is unavoidable due to the plastically deformed materials generated from the cutting and shearing phenomenon. Compared to macro milling, the size ratio between burr and micro-milling profile is extremely large making the removal process extremely challenging. Due to the challenge, this paper presents the investigation of critical factors in burr formation such as tool cutting edge radius, Rc using the finite element (FE) approach. The first part of the investigation consists of the validation of the FE simulation results with the experimental by comparing the generated cutting force, and the second part focused on the virtual experiment on the investigation of tool cutting edge radius to the burr formation on the machined dimple profile. In the simulation of inclined dimple milling, the 3D model of solid carbide (WC) ball end mill (BEM) tool contact with the round Aluminum Alloy 6061-T6 specimen model at 45° inclination angle to form the dimple profile and the characteristic of the burr profile measured directly on the deformed specimen model. Based on the results, it was found the cutting edge radius, directly proportional to the cutting force and significantly influence the burr formation in inclined dimple milling. Malaysian Tribology Society (MYTRIBOS) 2023-09 Article PeerReviewed pdf en http://umpir.ump.edu.my/id/eprint/39149/1/Using%20Finite%20Element%20simulation%20to%20investigate%20the%20effect%20of%20cutting.pdf Mohd Ali Hanafiah, Shaharudin and Ahmad Razlan, Yusoff (2023) Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation. Jurnal Tribologi, 38. pp. 49-68. ISSN 2289-7232. (Published) https://jurnaltribologi.mytribos.org/v38/JT-38-49-68.pdf
spellingShingle TA Engineering (General). Civil engineering (General)
TS Manufactures
Mohd Ali Hanafiah, Shaharudin
Ahmad Razlan, Yusoff
Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
title Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
title_full Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
title_fullStr Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
title_full_unstemmed Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
title_short Using Finite Element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
title_sort using finite element simulation to investigate the effect of cutting edge radius on burr formation for inclined dimple milling operation
topic TA Engineering (General). Civil engineering (General)
TS Manufactures
url http://umpir.ump.edu.my/id/eprint/39149/1/Using%20Finite%20Element%20simulation%20to%20investigate%20the%20effect%20of%20cutting.pdf
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