Alternating-flank Cutting Strategy (AFCS) for Burr Minimization in Ultraprecise Single Point Cutting (USPC)

High-aspect-ratio V-grooves constitute microstructures used in surface functionalization applications to control wettability, drag reduction, cell migration, and open capillary microfluidics. However, their precise fabrication represents a crucial challenge in micro-manufacturing due to problems such as riblet deflection, tool wear, and burr formation. This thesis addresses the problem of burr formation by developing an alternating-flank cutting strategy (AFCS) for burr minimization. This study includes a brief overview of different single-point cutting (SPC) strategies, followed by a qualitative finite element analysis of the fabrication challenges. Furthermore, two burr quantitative assessment methods (average burr height and burr volume) were developed for burr characterization. Preliminary analysis suggests that burrs are formed due to plastic deformation and lateral material flow in SPC, which can be minimized through process parameters optimization. Finally, the uniformity of burr formation along the V-groove provides an essential insight into the stability of the process and will require subsequent investigations