For qualitative prediction of chip morphology and quantitative prediction of burr size,
2D and 3D finite element (FE) based turning models have been developed in this paper.
Coupled temperature-displacement machining simulations exploiting the capabilities of
Abaqus® with a particular industrial turning insert and a newly proposed geometrical
version of this insert have been performed. Limitations of 2D models in defining the chip
morphologies and surface topologies have been discussed. The phenomenological findings on
the Poisson burr (Side burr) formation using 3D cutting models have been highlighted.
Bespoke geometry of the turning insert has been found helpful in reducing the Poisson burr
formation, as it reduces the contact pressures at the edges of tool rake face-workpiece
interface. Lower contact pressures serve to decrease the material flow towards workpiece
edges (out of plane deformation). In contrast, higher contact pressures at tool rake
face-workpiece interface lead to more material flow towards workpiece edges resulting in
longer burr. Simulation results of chip morphologies and cutting forces for turning an
aluminum alloy A2024-T351 have been compared with the experimental ones. Finally, it has
been concluded that the newly proposed geometry of the insert not only decreases the burr
but also helpful in lessening the magnitude of tool-workpiece initial impact.