Abstract
This paper studies the burr formation mechanism in milling cross-connected microchannels, and investigates the influences of radial depth of cut ae, cutting speed v, feed speed vf and mesh size on the burr formation. A thin slotting cutter is carried out to fabricate cross-connected microchannels in a metal plate of thickness H. Two kinds of large burrs are produced in the meshes formed by two sets of perpendicular and cross-connected microchannels: flake-like burr and curl-like burr. Results indicate that when ae is equal to or slightly larger than H/2, flake-like burrs are formed. When ae is much larger than H/2, curl-like burrs are produced. Furthermore, curl-like burrs formed at low v are relatively longer than those formed at high v. High vf is unfavorable for the occurrence of long curl-like burrs. In addition, larger mesh is in favor of longer burrs due to its larger capacity.
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