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Numerical investigations on a modified design of turning insert to decrease machining burr
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DOI：10.1080/15376494.2025.2486747.png)
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Abstract
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This study introduces a geometrical modification to an existing commercial turning insert to reduce end-burr formation. The straight cutting edge is redesigned into a curved one, with three different radii (R = 6, 8, and 12 mm) tested. A finite-element machining model was first developed and validated for the straight cutting edge, comparing cutting forces and burr formation parameters (such as chamfer angle, height, and depth) with experimental studies on aluminum alloys. The model was then applied to simulate machining with the new curved insert design. The results show that increasing the curvature-from straight to R12, R8, and upto R6 mm-significantly delays burr initiation and propagation, leading to less exit-edge deformation and reduced end-burr formation. The modified insert design reduced end-burr height by 47-60% across the different curved radii, though side-burr (Poisson burr) increased by 23-29%. Additionally, the new design reduces the intensity of initial tool-workpiece impact, potentially extending tool life and reducing edge breakage and chipping. The modified design of the turning insert provides a more sustainable machining process, requiring less energy, time, and effort for deburring while improving insert's lifespan.
Keywords:
End burr
finite element cutting simulation
machining insert
cutting tool life
damage and fracture in machining
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Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering ManufactureIF0
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