Abstract Requirements on burr height and burr amount on machined parts are getting stricter. This leads to method development from manufacturing companies to predict burr distribution and its size along part edges. A deeper understanding of burr formation mechanisms will assist to more accurate model development. This study aims to analyze the exit burr formation, which is formed during orthogonal cutting of a brittle cast aluminum alloy. A customized digital image correlation (DIC) system with the help of a high-speed camera was used to measure the displacements fields. It calculates strain fields during burr initiation and development in orthogonal cutting of T7 heat-treated cast aluminum alloy ENAC-AlSi7Mg0.3 as well. Those results are then qualitatively compared with a numerical model of the burr with chamfer formation developed and simulated using a finite element method, to ensure a good correspondence between experiments and simulation. This model is used to complete the DIC study of burr with chamfer formation mechanisms during crack propagation leading to chamfer formation. The analysis of numerically obtained stress triaxiality fields and of DIC observations from experiments are compared to the assumptions made from analytical models. Finally, necessary improvements of an existing burr formation analytical model are proposed.

中文翻译：

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基于数字图像相关和数值建模的出口毛刺形成机制研究

摘要 对加工零件的毛刺高度和毛刺量的要求越来越严格。这导致制造公司开发方法来预测毛刺分布及其沿零件边缘的尺寸。更深入地了解毛刺形成机制将有助于更准确的模型开发。本研究旨在分析在脆性铸造铝合金的正交切削过程中形成的出口毛刺。在高速相机的帮助下，使用定制的数字图像相关 (DIC) 系统来测量位移场。它还计算了 T7 热处理铸造铝合金 ENAC-AlSi7Mg0.3 正交切削过程中毛刺产生和发展过程中的应变场。然后将这些结果与使用有限元方法开发和模拟的具有倒角形成的毛刺的数值模型进行定性比较，以确保实验和模拟之间的良好对应。该模型用于完成毛刺的 DIC 研究，在裂纹扩展导致倒角形成过程中具有倒角形成机制。将数值获得的应力三轴场分析和实验中的 DIC 观察结果与分析模型所做的假设进行了比较。最后，提出了对现有毛刺形成分析模型的必要改进。该模型用于完成毛刺的 DIC 研究，在裂纹扩展导致倒角形成过程中具有倒角形成机制。将数值获得的应力三轴场分析和实验中的 DIC 观察结果与分析模型所做的假设进行了比较。最后，提出了对现有毛刺形成分析模型的必要改进。该模型用于完成毛刺的 DIC 研究，在裂纹扩展导致倒角形成过程中具有倒角形成机制。将数值获得的应力三轴场分析和实验中的 DIC 观察结果与分析模型所做的假设进行了比较。最后，提出了对现有毛刺形成分析模型的必要改进。