Burr formation during milling of wrought aluminum alloys

In this article, a multi-level experimental study on dry milling of 2024-T351 and 6061-T6 aluminum alloys is used to prescribe an operational window to control and minimize burr height (Bh) in milling. Maximum height of exit burr and exit up milling side burr were measured. Statistical tools were then used to define the dominant process parameters on Bh. The effects of feed rate, depth of cut, friction, tool coating, insert nose radius (RƐ) and material properties on milling burrs profiles are discussed. The experimental results show that machining with larger RƐ leads to bigger exit bottom burr and smaller exit up milling side burr. In addition, coated tools significantly affect Bh in slot milling operations.