During machining, burrs are produced along a part's edges, which can affect a final product lifetime or its efficiency. Moreover, time-consuming and expensive techniques are needed to be applied to remove such burrs. Therefore, companies attempt to reduce burrs formation during machining by manipulating the cutting conditions. This study aims to analyze and quantify the effect of a wide number of parameters on burr formation, resulting from different mechanisms, during orthogonal cutting of AlSi alloys. A highly developed experimental methodology combining high-speed camera recording, laser scanning, and in situ deburring system is used for this study. A statistical analysis is then applied to evaluate relations between controlled parameters and the occurrence of exit burrs morphologies. The results show that the uncut chip thickness influences burr types distribution along the exit edge and chamfer geometry. Among the cutting parameters and tool geometry, tool rake angle is the main parameter affecting burr height. Finally, it is found that none of the burrs geometrical characteristics ranges are piloted by cutting parameters or tool geometry. The assumption of a possible microstructural influence on these outputs is made.

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