Numerical Analysis of the Forming Mechanism of Exit Burrs in Metal Milling under Ice Boundary Constraint

In metal processing, exit burrs are usually inevitable, which is a huge challenge for high-precision manufacturing. This paper innovatively proposes an ice boundary constraint (IBC) method to actively suppress exit burrs to obtain better workpiece edge quality. Firstly, the formation mechanism of the exits burr is analyzed from the perspective of material flow at the edge of the workpiece, and the principle of the IBC method is explained. Secondly, a finite element model (FEM) is established to analyze the stress distribution and flow at the edge of the workpiece, so as to reveal the suppression mechanism of IBC on the exit burrs. Finally, the feasibility of IBC method and the validity of FEM are verified by the milling experiments. The experimental results show that the IBC method can reduce the exit burr height by 51.4% on average, and FEM can effectively predict the height of the exit burr. The IBC method proposed in this study can provide some reference and guidance for the active suppression of exit burrs in industry.