A quantitative model of burr formation for ductile materials which does not include fracture during orthogonal machining is proposed. The burr formation mechanism is divided into three parts—initiation, development, and formation of the burr with appropriate assumptions. The mechanisms proposed are based on the observation of the behavior of workpiece material during orthogonal machining on commercial plasticine. To validate the model, orthogonal machining inside a scanning electron microscope at low speed was done with a copper workpiece and A16061-T6, A12024-T4 and A1390 were cut on a modified milling machine over a range of cutting speeds.

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