Analytical modeling of Poisson burr formation in the machining of Al6061 with interface constraint

During the cutting process, unnecessary burrs frequently emerge along the cutting edge. To suppress the burrs generated in the process, an effective method is to provide interface constraint next to the workpiece, such as ice fixation machining. Although experimental evidence demonstrates that interface constraint effectively inhibits burrs, the understanding of its inhibitory mechanism remains limited. In this paper, the suppression mechanism of interface constraint on Poisson burr is analyzed, and an analytical model for predicting the size of Poisson burr with interface constraint is established. The model can predict the height and thickness of the Poisson burr, and it is verified by the finite element method and experiment. The inhibition effects of interface constraint on the Poisson burr under different workpiece strengths, cutting depths, cutting widths, tool rake angles, and constraint strengths are compared. The results show that interface constraint effectively reduces Poisson burr size, and the prediction model accurately describes both the size and shape of the Poisson burr. Workpiece material, tool rake angle, cutting depth, and constraint strength all significantly impact the size of the Poisson burr. Consequently, this paper offers enhanced insight into the mechanism of suppressing Poisson burrs by adding interface constraint and provides a theoretical reference for optimizing machining parameters.

Automated summary

In this paper, the suppression mechanism of interface constraint on Poisson burr is analyzed, and an analytical model for predicting the size of Poisson burr with interface constraint is established. The model can predict the height and thickness of the Poisson burr, and it is verified by the finite element method and experiment. The inhibition effects of interface constraint on the Poisson burr under different workpiece strengths, cutting depths, cutting widths, tool rake angles, and constraint strengths are compared.