Analytical and experimental investigation of improved burr morphology prediction at the top edge in metal machining

Previous research on analytical models used to predict burr size in machining operations has usually been limited to simple geometries and mechanics models. This paper investigates the material side-flow and Poisson burr formation mechanism. An improved analytical model is developed to describe the surface (subsurface) plastic deformation and Poisson burr morphology. First, the theoretical model is established based on mechanical, geometrical, and material property considerations. Then, machining experiments are performed on high-purity copper, and the proposed model is validated by comparing the predicted burr height and thickness to the experimental measurements. The results show that the developed model provides two new methods to predict burr dimensions with considerable accuracy and that this model is suitable for ductile materials. Additionally, this article offers a basis for minimizing the energy required during deburring, suppressing the formation of burrs, and optimizing the machining parameters.