Modeling of Top Burr Formation in Micro-End Milling of Zr-Based Bulk Metallic Glass

Abstract In this study, an analysis is presented for the formulation of a model in top burr formation to estimate the width of the top burrs formed in micro-end milling process. In this analysis, the width of the top burrs, considered to be the measure of burr size of top burrs, represents the extent of burr formation. The model is applied to quantify the burr formation in Zr-based bulk metallic glass, an amorphous metallic alloy. In this study, micromilling experiments were carried out on the bulk metallic glass work material at different levels of feed rate, axial depth of cut, and cutting speed to compare the experimental values of top burr width with the predicted values. Analysis is carried out to characterize top burr formation based on the experimental results of burr sizes in the up-milling and down-milling side edges, and the influential effects of the cutting parameters on the burr formation are analyzed.