Shaping Burrs are produced at the edge of a workpiece when a cutter exits it. It causes difficulties in manufacturing and assembly stages. Several attempts were made to minimize burr to suppress deburring to improve productivity. Deburring of the surface in shaping operation in railways industry and other industries is a great problem. An investigation on burr formation at the exit edge of aluminum alloy (4600-M) flats in shaping operation is done in this work under dry environment. It is found out that burr is negligible at 150 exit edge bevel angle. Distribution of shear stress is analyzed using FEM to validate the experimental results. It is found that maximum equivalent stress and deformation at different points on the 150 exit edge bevel angle become minimum justifying the experimental observation. Hence, an exit edge bevel of 150 may be adopted to have minimum burr formation.