I always like to run my roughing tool 1st, then my chamfer tool, and followed with my finish tool. This does well at keeping the burr to a minimum. Try looking into weiler deburr brushes. I had lots of success getting all my production parts (Inconel and titanium) burr free. I will attach link. https://www.weilerabrasives.com/catalog/application/deburring

My general rule of thumb which always depends on the workholding rigitity, tool holder, and the tool geometry itself. I like to use a 5% step over for exotic materials(Inconel and waspoloy) 10% step over for titanium, 15% for stainless, 20% for most steels and 25% for aluminum. This is just starting parameters and there is more to take in to consideration.

I would use a face mill which can cover the surface in question( if possible) I would leave the dimension heavy .001-.002 for grind.

Typically I will zig zag on softer materials. When harder material I always climb cut.