An Experimental Analysis on the Formation of Top Burrs in Micro End Milling
Edge condition of machined features plays a vital role in their functionality. For micro-parts, the edges generated during machining need to be free of burrs. Bulk metallic glass (BMG), an amorphous alloy is an important material that is used in making micro-devices and parts. The present study focusses on the understanding of the influence of the cutting parameters on the width of top burrs formed in full immersion micro end milling of Zr-based bulk metallic glass. To evaluate the influence of cutting parameters on the top burr width, experimental plan has been designed following design of experiments (DOE). Modelling of the width of top burrs has been carried out using response surface methodology. The experimental results showed that feed per tooth and axial depth of cut have significant influence on the burr size. In the chosen domain of cutting parameters, top burr width increased with increase of axial depth of cut. Furthermore, the analysis revealed that burr size decreased with increase in feed rate. At very low feed rate, increased ploughing effect resulted in increased burr width. Keywords - Micro Milling; Burr; BMG; RSM; ANOVA; Response Surface Analysis.