During the machining process, high mechanical and thermal loads occur at the cutting edge. Such loads can cause tool failure. Specifically non-uniform and sharp cutting edges that have a low cutting edge stability lead to such failures. In order to enhance the tool performance, the cutting edges are prepared by manufacturing both a pre-defined cutting edge geometry, and an appropriate cutting edge roughness. This paper describes the use of a low-cost marking laser for the preparation of cutting edges as an alternative to conventional preparation techniques, such as brushing or blasting. Cutting edge radii of 9–47 μm can be prepared with a machining accuracy of 1.5 μm. The maximum preparation time for an individual cutting edge is approximately 10 s. Uncoated indexable inserts manufactured in this way were tested in a face milling operation. The results of these investigations (using prepared cutting edges) show both an increase in tool life and an improved surface roughness of the machined workpieces compared to those using non-prepared cutting edges.

Remaining burrs after machining pose a severe risk for components life, if the burrs get loose. To reduce or eliminate burrs several deburring technologies are applied. To choose a deburring system and to reveal the results of deburring it is necessary to be able to measure burrs. The results of a round robin test conducted within the working group of burrs within the CIRP (International Academy for Production Engineering) to compare different burr measurement systems are presented.

Increasing demands on function and performance call for burr-free workpiece edges after machining. Since deburring is a costly and non-value-added operation, the understanding and control of burr formation is a research topic with high relevance to industrial applications. Following a review of burr classifications along with the corresponding measurement technologies, burr formation mechanisms in machining are described. Deburring and burr control are two possible ways to deal with burrs. For both, an insight into current research results are presented. Finally, a number of case studies on burr formation, control and deburring along with their economic implications are presented.

The increasing power density in engine manufacturing as well as the complexity of parts in automotive production demand for an entire control of burr formation especially in regard of intersecting holes. This paper presents an approach to control burr formation concerning reproducible generation of burrs depending on intersecting geometry and process parameters. Therefore two process models describing burr formation and burr cap formation and results of experimental investigations of different workpiece materials (AISI 4140H (42CrMo4), 226D AlSi9Cu3)) were combined.