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Two face milling cutter systems, both with PCBN (polycrystalline cubic boron nitride) tools, were used to study burr formation in high-speed machining of grey cast iron under various cutting conditions. Surface roughness parameters R a and R t , tool life (based on¯ank wear, VB max ) and burr formation (length of the burr, h) were recorded and used for comparing machining performance. The best performance in terms of tool life and surface roughness was obtained with the milling cutter system consisting of 24 teeth and 24 square wiper inserts. Machining with this cutter con®guration produced acceptable surface roughness values, well below the rejection criterion, after machining a batch of 3000 motor blocks in addition to achieving a signi®cant reduction in the burr length. NOTATIONdoc depth of cut (mm) f z feed per tooth (mm) h maximum roughness height (mm) PCBN polycrystalline cubic boron nitride R a average roughness (mm) R t maximum roughness height (mm) V c cutting speed (m/min) V f feed rate (mm/min) VB max maximum¯ank wear (mm) m exit angle (deg) À r approach angle (deg)

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