Experimental research on the top burr formation in micro milling.

The top burr is the common problem that faced in micro milling and presents the significant effect on the machining quality. The top burr minimization is desired to achieve high precision machining in micro milling. In this paper, the top burr formation mechanisms are analyzed, and then micro milling experiments are conducted to investigate the effect of machining parameters on the morphology and size of top burr. It is found that the top burr formation is caused by the unexpected material plastic side flow at the top side, which is an unresisted free surface with low support stiffness during micro milling. The unseparated chips that are connecting on the top side greatly increase top burr. The optimal machining strategies are suggested to minimize top burr. [ABSTRACT FROM AUTHOR]