Research on the modeling and experimenting of burr formation process in double-edged micro-plat end milling operation

Burrs generated in micro-milling operation have a significant impact on the surface quality and operational performance of the finished microstructures. In order to gain a better recognition of burr generation process, 3-dimensional double-edged micro-flat end milling operation FEM models on Ti-6Al-4V have been established. Burrs occurred in simulation can be classified into three types: entrance burr, exit burr, top burr. Their formation processes and causes are well investigated and analyzed, moreover, a series of experiments are conducted to validate the burr morphologies which are received in simulation. At last, the effect of cutting parameters on top burr size is studied through orthogonal experiment on Ti-6Al-4V, it can be concluded that the axial depth of cut has the greatest effect on top burr size, and the effect of spindle speed on top burr size is the least.