Burr Controlling in Micro Milling with Supporting Material Method

A novel method is presented in order to prevent burrs formation in micro milling process. Burrs description and the minimum cutting depth are discussed firstly. Then burr formation mechanism is analyzed and it is found that negative shear of tool plays an important role in burr formation. Instant adhesive was selected as supporting material to extend the workpiece boundary. Burrs will exist on the supporting material instead of workpiece material. Experiments are carried out on a micro machine and beryllium bronze is machined with micro end milling tools. The experimental results validate the feasibility of this method and most burr-free components are obtained.