Statistical investigation on burrs thickness during milling of 6061-T6 aluminium alloy

Burr formation is a research topic with high relevance to industrial applications. According to deburring perspective, the thickness of the burr is of interest as it describes the time and method necessary for deburring of the machined part. Burr thickness (Bt) measurements are costly and non-value-added operations which in most of the cases require the use of Scanning Electron Microscope (SEM) for accurate burr characterization. This study presents an experimental study to evaluate parameters affecting the burr thickness and to search for correlation between the cutting parameters and the burr thickness. Amongst investigated burrs, exit up milling side burr is found to be highly controlled with machining parameters. It has shown a high correlation rate with tangential force (Ft). Linear first order mathematical models are developed to predict exit up milling side burr thickness and Ft as a function of feed per tooth and depth of cut.