A burr formation FEM has been presented in this paper based on ANSYS/LS-DYNA. From the simulationresult of strain and stress distribution, the mechanism of the burr formation process is analyzed. Also, three differentstages in burr formation process which have different mechanism have been studied. A chip separation criterion basedon the critical value of the strain failure is introduced into the analytical model. The concept of negative shear zoneand negative shear angle are proposed in study. Finite element model generated here provided a numerical analysismethod to solve the problem of burr formation and physical insight into the fundamental burr formation mechanism.
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