Finite element-based study of the mechanics of microgroove cutting

Keith A. Bourne, Shiv Gopal Kapoor, Richard E. DeVor

Research output: Contribution to journalArticlepeer-review


In an earlier paper, a high-speed microgroove cutting process that makes use of a flexible single-point cutting tool was presented. In this paper, 3D finite element modeling of this cutting process is used to better understand process mechanics. The development of the model, including parameter estimation and validation, is described. Validation experiments show that on average the model predicts side burr height to within 2.8%, chip curl radius to within 4.1%, and chip thickness to within 25.4%. The model is used to examine chip formation, side burr formation, and exit burr formation. Side burr formation is shown to primarily occur ahead of a tool and is caused by expansion of material compressed after starting to flow around a tool rather than becoming part of a chip. Exit burr formation is shown to occur when a thin membrane of material forms ahead of a tool and splits into two side segments and one bottom segment as the tool exits a workpiece.

Original languageEnglish (US)
Article number031015
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Issue number3
StatePublished - Jun 1 2013

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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