The formation of exit burr in drilling metals is analyzed by finite element method. The simplified burr formation model is suggested for the complex mechanism of burr formation in drilling on the basis of experimental data. Using the model the magnitude of burr is predicted and the effect of material properties of workpiece and cutting condition on burr formation is analyzed in the present study. The suggested model is verified by comparing simulation results and experimental ones. The predicted size and shape of burr are in good agreement with those observed by experiment.