Formation mechanism and geometry characteristics of exit-direction burrs generated in surface grinding of Ti-6Al-4V titanium alloy

The formation mechanism and geometry characteristics of exit-direction burrs in surface grinding of Ti-6Al-4V titanium alloy have been investigated based on finite element analysis in this article. Three types of burrs, i.e., positive burrs, negative burrs, and residual burrs, are classified; meanwhile, the formation stages of different burrs are defined. The effects of three critical parameters in surface grinding (i.e., grinding speed, uncut chip thickness, and negative rake angle of CBN grains) on burr formation are discussed. Results obtained display that the burr height and root thickness increase with decreasing of grinding speed and increasing of uncut chip thickness and negative rake angle magnitude of CBN grains. A positive burr, which is in favor of being removed easily and therefore lowering the machining cost, could be generated when a parameter combination (i.e., a higher grinding speed, a smaller uncut chip thickness, and a smaller magnitude of negative rake angle of CBN grain) is utilized.