Burrs are a common problem in metal processing, such as drilling, turning, milling, and sheet metal cutting. . .
One of the hazards of burrs is that they are easy to cut! To remove burrs, a secondary operation called deburring is usually required. 3 deburring and edge finishing of precision parts can account for 30% of the cost of the finished part. Also, secondary finishing operations are difficult to automate, so burrs really become a tricky problem.
How to solve BURRS
1 Manual deburring
This is a more traditional and commonly used method, using files (manual files and pneumatic files), sandpaper, belt sanders, grinding heads, etc. as auxiliary tools.
Disadvantages: The labor cost is expensive, the efficiency is not very high, and it is difficult to remove complex cross holes.
Applicable objects: The technical requirements for workers are not very high, and it is suitable for aluminum alloy die castings with small burrs and simple product structure.
2 Die deburring
Deburring is carried out by using a production die and a punch.
Disadvantages: It requires a certain amount of die (rough die, fine die) production cost, and may also need to make a shaping die.
Applicable objects: It is suitable for aluminum alloy die castings with simple parting surfaces, and the efficiency and deburring effect are better than those of manual work.
3 Grinding and deburring
This type of deburring includes vibration, sandblasting, rollers, etc., and is currently used by die-casting plants.
Disadvantages: There is a problem that the removal is not very clean, and subsequent manual processing of residual burrs or other methods of deburring may be required.
Applicable objects: suitable for small aluminum alloy die castings with large batches.
4 Frozen deburring
Use cooling to quickly embrittle the burrs, and then spray projectiles to remove the burrs. The price of the equipment is about 200,000 or 300,000;
Applicable objects: Suitable for aluminum alloy die castings with small burr wall thickness and small volume.
5 Hot blast deburring
Also called thermal deburring, explosion deburring. By introducing some flammable gas into an equipment furnace, and then through the action of some media and conditions, the gas is instantly exploded, and the energy generated by the explosion is used to dissolve and remove the burr.
Disadvantages: expensive equipment (millions of dollars), high technical requirements for operation, low efficiency, side effects (rusting, deformation);
Applicable objects: Mainly used in some high-precision parts fields, such as automobile and aerospace precision parts.
6 Deburring of engraving machine
The price of equipment is not very expensive (tens of thousands).
Applicable objects: It is suitable for simple space structure and simple and regular deburring position.
7 Chemical deburring
Using the principle of electrochemical reaction, the parts made of metal materials can be automatically and selectively deburred.
Applicable objects: suitable for internal burrs that are difficult to remove, suitable for small burrs (thickness less than 7 wires) of products such as pump bodies and valve bodies.
8 Electrolytic deburring
An electrolytic machining method for removing aluminum alloy die-casting burrs by electrolysis. Electrolytic deburring is suitable for removing burrs in hidden parts of aluminum alloy die castings, cross holes or parts with complex shapes. The production efficiency is high, and the deburring time is generally only a few seconds to tens of seconds.
Disadvantages: The electrolyte is corrosive to a certain extent, and the vicinity of the burr of the parts is also subjected to electrolysis, the surface will lose its original luster, and even affect the dimensional accuracy. The aluminum alloy die-casting should be cleaned and rust-proofed after deburring.
Applicable objects: It is suitable for deburring of gears, connecting rods, valve bodies and crankshaft oil passage holes, as well as rounding of sharp corners.
9 High-pressure water jet deburring
Using water as a medium, it can use its instantaneous impact force to remove burrs and flashes generated after processing, and at the same time, it can achieve the purpose of cleaning.
Cons: Expensive equipment
Applicable objects: mainly used in the heart of automobiles and hydraulic control systems of construction machinery.
10 Ultrasonic deburring
Conventional vibration grinding is difficult to deal with burrs such as holes. The typical abrasive flow machining process (two-way flow) pushes the abrasive through two vertically opposite abrasive cylinders to make it flow back and forth in the channel formed by the workpiece and the fixture. The entry and flow of abrasive into and through any area that is restricted will produce an abrasive effect. The extrusion pressure is controlled at 7-200bar (100-3000 psi), suitable for different strokes and different cycle times.
Applicable objects: It can handle 0.35mm microporous burrs, no secondary burrs are generated, and the fluid characteristics can handle complex position burrs.
11 Abrasive flow deburring
Conventional vibration grinding is difficult to deal with burrs such as holes. The typical abrasive flow machining process (two-way flow) pushes the abrasive through two vertically opposite abrasive cylinders to make it flow back and forth in the channel formed by the workpiece and the fixture. The entry and flow of abrasive into and through any area that is restricted will produce an abrasive effect. The extrusion pressure is controlled at 7-200bar (100-3000 psi), suitable for different strokes and different cycle times.
Applicable objects: It can handle 0.35mm microporous burrs, no secondary burrs are generated, and the fluid characteristics can handle complex position burrs.
12 Magnetic deburring
Magnetic grinding is that under the action of a strong magnetic field, the magnetic abrasives filled in the magnetic field are arranged along the direction of the magnetic field lines, adsorbed on the magnetic poles to form "abrasive brushes", and generate a certain pressure on the surface of the workpiece, and the magnetic poles are driving the "abrasives". While the brush is rotating, it keeps a certain gap and moves along the surface of the workpiece, so as to realize the finishing of the surface of the workpiece.
Features: low cost, wide processing range, convenient operation
Process elements: grindstone, magnetic field strength, workpiece speed, etc.
13 Robot grinding unit
The principle is similar to manual deburring, except that the power is turned into a robot. With the support of programming technology and force control technology, flexible grinding (change of pressure and speed) is realized, and the advantages of robot deburring are prominent.
Compared with humans, robots have characteristics: improved efficiency, improved quality, and high cost
Burrs in Special Challenge Milled Parts
In milled parts, deburring is more complex and more expensive, as multiple burrs are formed at different locations of different sizes. This is where choosing the correct process parameters to minimize burr size becomes even more important.
Post time: Sep-29-2022
