Burr formation in milling cross-connected microchannels with a thin slotting cutter

This paper studies the burr formation mechanism in milling cross-connected microchannels, and investigates the influences of radial depth of cut ae, cutting speed vv, feed speed vfvf and mesh size on the burr formation. A thin slotting cutter is carried out to fabricate cross-connected microchannels in a metal plate of thickness H. Two kinds of large burrs are produced in the meshes formed by two sets of perpendicular and cross-connected microchannels: flake-like burr and curl-like burr. Results indicate that when ae is equal to or slightly larger than H/2, flake-like burrs are formed. When ae is much larger than H  /2, curl-like burrs are produced. Furthermore, curl-like burrs formed at low vv are relatively longer than those formed at high vv. High vfvf is unfavorable for the occurrence of long curl-like burrs. In addition, larger mesh is in favor of longer burrs due to its larger capacity.