Study on burr formation in micro-machining using micro-tools fabricated by micro-EDM

The purpose of this study is to study burr format in micro-machining using micro-tools. The micro-tools employed are fabricated by micro-EDM using the wire electro-discharge grinding (WEDG) method in the micro-EDM/milling machine we had already developed. Micro tungsten-carbide tool with a minimum of 31-mu m in diameter had been fabricated. The simple-shaped micro-tool fabricated is able to perform the micro-machining operation which is a combination of micro-milling and grinding processes. Micro-slot and micro thin-walled structure had been produced on Al 6061-T6 materials successfully. Burr formation in micro-machining is investigated experimentally and classified into four types: primary burr, needle-like burr, feathery burr and minor burr. Formation mechanisms of these burrs and the relationship between their existence and the machining condition are discussed. (c) 2006 Elsevier Inc. All rights reserved.