The semantic differential (SD) method was used to characterize the size and shape of burrs created under various cutting conditions, drill size, tool geometry and coatings. Human subjects visually rated the burr using a SD evaluation form. Significant differences were found in tool type and feed rate. A high performance drill with titanium-nitride coating and a high depth/diameter ratio, yielded minimum burr. A lower feed rate resulted in less burr formation in the majority of the cases. Three primary factors emerged, and accounted for 83% of the variances. Factor scores were mapped into the SD space to show the effect of treatments.