One of the major issues of drilling operations pertains to the formation of burrs, which greatly influences the accuracy of the manufactured parts, and, thus, the capability to meet the desired performance of the part. To remove or prevent these burrs, their geometry must be measured accurately, even though they are sharp and irregular in shape. The accurate measurement of the geometry of a burr will lead to the development of a proper deburring method. In this work, the authors describe a simple and convenient new measurement technique for drilling burr profiles and a developed drilling burr measurement system based on surface area. The new method presented in this research aims at providing a comparative evaluation of the height, arc length and area of the burr, as well as its geometrical characteristics. When the average height and arc length measurement methods are compared with the area measurement method, large deviations in burr height are detected. In particular, these deviations increase more in non-uniform burrs. In the measurement of burr size, the new developed method is based on area measurement and is carried out using a computer. Therefore, there is no deviation between the measurements. In contrast, the average deviation ranges for the height and arc length measurement methods are found to be 9.94–48.14% and 6.07–18.82%, respectively.
