is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. A B S T R A C TBurr formation during machining is an important issue in industry. It causes an additional deburring operation, which is time consuming and has a negative economic impact. This study aims to analyse burr formation mechanisms and its accumulation in successive passes during orthogonal cutting of a cast aluminium alloy. A customized experimental setup was developed, which includes a high speed imaging system and a laser profilometer. A design of experiments using the setup mentioned previously is carried out and a methodology for geometric burr characterization is developed and applied. Furthermore, statistical representation of the obtained results is performed, which allows the understanding of the geometric heterogeneity influence associated to burr formation mechanisms and to work material microstructure.Based on the exit burr analysis, new geometrical criteria are proposed for the characterisation and the definition of two main burr formation mechanisms.The influence of cutting parameters on burr morphology along the workpiece exit edge is investigated in depth. The results show that two types of burrs can be produced simultaneously along the workpiece exit edge due to the work material microstructure heterogeneity. The results present as well the influence of low uncut chip thickness that leads to a higher proportion of burrs without chamfer. This type of burr is higher and more propice to burr accumulation. After performing several cutting passes, these burrs may be eliminated and replaced by a burr with chamfer.

This study evaluated the residual stresses induced by brazing and grinding submicron Al 2 O 3 , using different methods. Energy dispersive x-ray spectrometry analysis (EDX) of 72Ag-Cu filler and filler/WC-Co interface showed evidence of atomic diffusion and possible formation of titanium oxide layers between the joint and the bonding materials. An analytical model supported by the finite element method (FEM) based on strain determination due to the difference in variation of thermal expansion was used to assess the stress distribution at the coupling interface and in bulk materials. The model took into account the evolution of the YoungÕs modulus and of the thermal expansion with temperature. The model could be used to follow strain and stress evolutions of the bonded materials during the cooling cycle. The maximum stress rose above 2300 MPa at the center of the 100 3 100 3 3 mm ceramic plates. The residual stresses on the external surface of ceramic were investigated by x-ray diffraction (XRD) and indentation fracture method (IFM). After brazing and grinding the plate, the principal stresses were 128.1 and 94.9 MPa, and the shear stress was 220.1 MPa. Microscopic examination revealed grain pull-out promoted by the global residual stresses induced by the brazing and grinding processes. The surface stresses evaluated by the different methods were reasonably correlated.