Abstract Previous investigations on the theoretical model to predict burr dimensions have normally been confined to a single geometric model, and the findings that have been proposed rarely take into account the influence of multi-physics factors on burr formation in the complex machining process. This paper proposes an analytical model to reveal subsurface plastic deformation behavior in machining of ductile material. This model is developed based on coupled thermo-mechanical factors. More importantly, the material property and tool edge arc are taken into consideration. According to the proposed model, the two approaches are presented to predict Poisson burr height and root thickness. Moreover, the material flow and burr formation mechanism are further investigated at great length. The effects of machining parameters and material properties on burr formation are analyzed and discussed in terms of plastic deformation behavior. The results show that this proposed model can describe burr morphology and predict burr size accurately. Poisson burr generation has a great sensitivity to machining parameters, as well as material property, and the transition of burr morphology is caused by severe lateral material flow owing to material softening effect at high temperature. There is the synchronous interaction between machining parameters and material property influencing burr formation. As a result, this study provides a valuable theoretical reference and basis for the deburring energy minimization, high surface quality, and machining parameters optimization.

中文翻译：

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塑性金属加工中泊松毛刺形成的解析模型与实验验证

摘要 以往对毛刺尺寸预测理论模型的研究通常局限于单一的几何模型，并且所提出的研究结果很少考虑复杂加工过程中多物理因素对毛刺形成的影响。本文提出了一种分析模型，以揭示韧性材料加工中的次表面塑性变形行为。该模型是基于耦合的热机械因素开发的。更重要的是，考虑了材料属性和刀具边缘弧度。根据所提出的模型，提出了两种方法来预测泊松毛刺高度和根部厚度。此外，进一步深入研究了材料流动和毛刺形成机制。从塑性变形行为的角度分析和讨论了加工参数和材料特性对毛刺形成的影响。结果表明，该模型能够准确地描述毛刺形态并预测毛刺尺寸。泊松毛刺的产生对加工参数和材料性能有很大的敏感性，毛刺形态的转变是由于材料在高温下的软化作用造成的严重横向材料流动引起的。影响毛刺形成的加工参数和材料特性之间存在同步相互作用。因此，本研究为去毛刺能量最小化、高表面质量和加工参数优化提供了有价值的理论参考和依据。