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

The purpose of this study is to study burr formation 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-μm 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.