Metal Deburring: Process, Methods, and Importance in Manufacturing

DALIAN, China - Sept. 7, 2025 - PRLog -- What Are Burrs and Why Do They Form?

Burrs form when metal is plastically deformed rather than cleanly sheared during machining or cutting. They typically occur at the exit point of a cutting tool or where the material is separated. Common causes include:

• Tool wear causing poor cutting action
• Improper machining parameters such as excessive feed rate
• Material ductility (softer metals like aluminum and copper tend to produce longer burrs)
• Thermal effects during cutting that soften edges

Metal deburring refers to the process of removing unwanted burrs from metal parts. Most of these unnecessary protrusions are accidentally generated, which can affect the correct assembly of parts, affect their performance, and pose safety hazards during use.

Common types of burrs on metal parts

Burrs are unwanted protrusions, similar to sharp edges. They have different shapes and sizes. In fact, their formation methods also vary depending on the burrs.

Therefore, you must understand the types of burrs in order to choose the correct metal deburring method. The following lists common types of burrs on metal parts.

1. Flip over burrs

Flipped burrs are the most common type of burrs. They are usually formed by cutting tools pushing metal out of the edge without thorough separation. This will cause metal misalignment and folding. This type of burr is common in ductile metals such as aluminum and copper, especially after mechanical processing such as drilling, turning, and milling.

2. Breakout Burrs

The formation of breakout burrs originates from its name itself. Usually, machines or tools can cause material fracture or breakage when they leave their surface. This will cause damage and burrs. They are particularly common in brittle materials such as hard plastics.

3. Poisson (compression) burrs

Poisson burrs, also known as compression burrs, are formed due to the lateral deformation of materials. This is driven by compressive force, causing the edges to bulge.

They usually affect softer and more ductile materials, especially in turning and forming processes. They usually appear during the cutting process.

4. Tear off burrs

When materials break or tear due to cutting tool wear, tearing burrs will be generated. If too much force is applied, it will form large burrs that are difficult to predict and have sharp tips. This situation usually occurs when rough machining operations are used and there is little or no maintenance of the tool.
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