Research on Milling Burrs of ALSI304 Stainless Steel with Consideration of Tool Eccentricity

Burrs are a significant machining defect affecting the quality of precision parts, and tool eccentricity may substantially influence milling burrs. Using AISI 304 stainless steel as the workpiece material, a three-dimensional thermo-mechanical coupled model for slot milling was constructed based on an explicit dynamics model. Combining the Johnson–Cook (J-C) constitutive model with the J-C shear failure criterion, simulations were conducted to obtain burr dimensions, cutting temperature distributions, and cutting force waveforms under different tool eccentricity directions and magnitudes. Results: As the eccentricity increases, the temperature of the top burr rises, and both the width of the top burr and the thickness of the exit side burr significantly increase. Under simulated conditions, the width of the top burr in down milling side increased by up to 70%. The burr dimensions under different eccentricity directions can differ by approximately 40%. Groove milling experiments revealed similar burr shapes between experimental and simulated results. Furthermore, the simulated cutting force waveforms aligned with those in the literature, indicating the reliability of the simulation outcomes. Based on these findings, it can be concluded that tool eccentricity significantly affects the dimensions of top burrs and exit side burrs. The width of top burrs and the thickness of exit side burrs are positively correlated with the tool eccentricity distance, while exit bottom burrs remain unaffected by eccentricity. These research results provide valuable reference for burr suppression in practical machining operations.