Minimization of exit burr in face milling of medium carbon steel by exit edge beveling

Elimination, or reduction, of burrs formed during machining is drawing focus of manufacturers and researchers since long or suppressing a burr regarding its formation or removal of it through a suitable deburring process. Deburring is an extra process often required to undertake, and it involves additional time and cost. Presence of burr may cause several problems, such as difficulty in assembly, dimensional inaccuracy, injury to the operator, etc. Like other industries, avoidance of burr on milled component surfaces in railways is of concern. In the present investigation, formation of burr in face milling is tried to reduce by beveling the exit edge of blocks of medium carbon steel (45C8) which is widely used in railways for manufacture of different components. Cutting conditions are also varied to observe the effect on burr formation. It is observed that at an exit edge bevel angle of 15°, negligible burr is formed at most of the cutting conditions undertaken, and hence, recommended.