Burr prediction due to flank wear in end-milling

A new model to predict burr formation due to tool wear of a cutting tool in end-milling is proposed. The model shows that the burr sizes vary according to flank wear of a cutting tool. A system was developed to simulate burr to be formed at each edge point on machined surfaces based on flank wear of a cutting tool and cutting conditions by using the proposed model. In addition, the experimental works of steel with a 0.45% carbon and aluminum alloy AlMg0.5Si with solid carbide tools was executed to investigate the relationship between burr size and tool flank wear, and comparison between experimental results and predicted results was discussed. The comparison results showed that the proposed model could help to predict burr size under the effect of tool flank wear with high accuracy.