A 3D finite element model was developed for the simulation of drilling burr formation processes of 304L stainless steel. The nonlinear thermo-elastic-plastic model simultaneously accounts for dynamic effects of mass and inertia, strain hardening, strain rate, automatic mesh contact with friction capability, material ductile failure and temperature-mechanical coupling. Material ductile failure criteria were proposed to simulate drilling burr formation. Based on a series of stress contours and the progressive deformation of the workpiece edge obtained from simulation, a drilling burr formation mechanism was proposed and divided into four stages: initiation, development, pivoting point, and formation stages with cap formation. The burr thickness is largely determined by the distance between the pre-defined machined surface and the pivoting point, while the burr height is determined by the positions of the pivoting point and the cap formation. The FEM simulation demonstrates the dominant roles of negative shearing and bending mechanisms in the drilling burr formation process. The simulation results coincide with phenomenological observations of burr geometry from drilling 304 stainless steel and plasticine work materials. [S1087-1357(00)01202-8]

Issue Section:
Technical Papers
Keywords:
stainless steel, machining, manufacturing processes, finite element analysis, ductility, failure (mechanical), thermoelasticity
Topics:
Drilling, Finite element analysis, Simulation, Stainless steel, Modeling, Deformation, Geometry, Stress, Failure, Drills (Tools), Finite element model
1.
Gillespie
,
L. K.
,
1979
, “
Deburring Precision Miniature Parts
,”
Precis. Eng.
,
1
, No.
4
, pp.
189
–
198
.
2.
Gillespie, L. K., 1975, “Hand Deburring of Precision Parts,” Bendix Aerospace, Kansas City Division, Report No. BDX 613–1443.
3.
Gillespie, L. K., 1975, “Burrs Produced by Drilling,” Bendix Corporation, Unclassified Topical Report BDX-613-1248, December.
4.
Takazawa, K., 1988, “The Academic Challenge of Burr Technology in Japan,” SME Deburring and Surface Conditioning Technique Conference.
5.
Stein, J., 1995, “Burr Formation in Precision Drilling of Stainless Steel,” Ph.D. dissertation, Dept. of Mech. Eng., University of California, Berkeley.
6.
Sofronas, A., 1975, “The Formation and Control of Drilling Burrs,” Ph.D. dissertation, University of Detroit.
7.
Lee, G. B., 1989, “Digital Control for Burr Minimization in Drilling,” Ph.D. dissertation, Univ. of California, Berkeley, April.
8.
Usui, E., and Shirakashi, T., 1982, “Mechanics of Machining—from ‘Descriptive’ to ‘Predictive’ Theory. In On the Art of Cutting Metals—75 Years Later,” Vol. PED-7, pp. 13–35, New York.
9.
Liu, C. R., Lin, Z. C., and Barash, M. M., 1984, “Thermal and Mechanical Stresses in the Workpiece During Machining,” High Speed Machining, PED Vol. 12, R. Kunanduri, K. Subramanian, and B. F. van Turkovich, eds., ASME, New York, pp. 181–191.
10.
Strenkowski
,
J. S.
, and
Carroll
,
J. T.
,
1985
, “
A Finite Element Model of Orthogonal Metal Cutting
,”
ASME J. Eng. Ind.
,
107
, pp.
349
–
354
.
11.
Klamecki
,
B. E.
, and
Kim
,
S.
,
1988
, “
On the Plane Stress to Plain Strain Transition Across the Shear Zone in Metal Cutting
,”
ASME J. Eng. Ind.
,
110
, pp.
322
–
325
.
12.
Komvopoulos
,
K.
, and
Erpenbeck
,
S. A.
,
1991
, “
Finite Element Modeling of Orthogonal Metal Cutting
,”
ASME J. Eng. Ind.
,
113
, pp.
253
–
267
.
13.
Lin
,
Z. C.
, and
Lin
,
S. Y.
,
1992
, “
A Coupled Finite Element Model of Thermo-Elastic-Plastic Large Deformation for Orthogonal Cutting
,”
ASME J. Eng. Ind.
,
114
, pp.
218
–
226
.
14.
Zhang
,
B.
, and
Bagchi
,
A.
,
1994
, “
Finite Element Simulation of Chip Formation and Comparison with Machining Experiment
,”
ASME J. Eng. Ind.
,
116
/3, pp.
289
–
297
.
15.
Marusich, T. D., and Ortiz, M., 1995, “A Finite Element Study of Chip Formation in High-Speed Machining,” Manufacturing Science and Engineering, MED-Vol. 2-1/MH-Vol. 3-1, E. Kannatey-Asiba, Jr., ed., ASME, New York, pp. 245–258.
16.
Shih
,
A. J.
,
1995
, “
Finite Element Simulation of Orthogonal Metal Cutting
,”
ASME J. Eng. Ind.
,
117
, pp.
84
–
93
.
17.
Huang
,
J. M.
, and
Black
,
J. T.
,
1996
, “
An Evaluation of Chip Separation Criteria for the FEM Simulation of Machining
,”
J. Manuf. Sci. Eng.
,
118
, pp.
545
–
553
.
18.
Obikawa
,
T.
, and
Usui
,
E.
,
1996
, “
Computational Machining of Titanium Alloy—Finite Element Modeling and a Few Results
,”
ASME J. Manuf. Sci. Eng.
,
118
, pp.
208
–
215
.
19.
Ceretti, E., Taupin, E., and Altan, T., 1997, “Simulation of Metal Flow and Fracture Applications in Orthogonal Cutting, Blanking, and Cold Extrusion,” CIRP Ann.
20.
Park, I. W., 1996, “Modeling of Burr Formation Processes in Metal Cutting,” Ph.D. dissertation, University of California, Berkeley, Department of Mechanical Engineering, May.
21.
Hibbit, Karlsson, and Sorenson, Inc., 1988, ABAQUS/Explicit User’s Manual, ver.5.3, Providence, RI.
22.
Kronenberg, 1966, Machining Science and Application, Pergamon Press.
23.
Kattus, J. R., 1975, Aerospace Structural Metals Handbook.
24.
Kalpakjian, S., 1997, Manufacturing Engineering and Technology, Addison-Wesley Publishing Company, Inc.
25.
Stephenson, D. A., and Agapiou, J. S., 1997, Metal Cutting Theory and Practice, Marcel Dekker, Inc.
26.
Reddy, J. N., 1993, An Introduction to the Finite Element Method, McGraw-Hill, Inc.
27.
DeVries, W. R., 1992, Analysis of Material Removal Processes, Springer-Verlag.
28.
Shaw, M. C., 1984, Metal Cutting Principles, Oxford University Press, New York.
29.
Black, J. T., and Huang, J. M., 1995, “Shear Strain Model in Metal Cutting,” Manufacturing Science and Engineering, MED-vol.2-1/MH-vol.3-1, pp. 283–302.
30.
Guo
,
Y. B.
, and
Dornfeld
,
D. A.
,
1998
, “
Finite Element Analysis of Drilling Burr Minimization with a Backup Material
,”
Trans. NAMRI/SME
,
XXVI
, pp.
207
–
211
.
Copyright © 2000
 by ASME
You do not currently have access to this content.