The Different Types of Deburring Processes and Their Advantages

The Different Types of Deburring Processes and Their Advantages

Many different deburring processes can be used to ensure that your components and tools can endure wearing and tear and are still functional. Some common ones include mechanical deburring, tumbling, laser and high-definition plasma deburring, and electrochemical deburring. Having a good understanding of what is deburring tool used for and the kinds of deburring processes can help you to know which method is best for you.

Electrochemical Deburring

Electrochemical deburring processes are used to remove burrs from hard metals. They provide an excellent surface finish and are safe. The process is particularly beneficial for difficult-to-access workpieces.

The electrochemical deburring procedure is highly accurate and selective for removing burrs on hard metals. It is also suitable for deburring gears.

To perform electrochemical deburring, the workpiece is submerged in an electrolyte solution. A cathodic tool is positioned between the workpiece and the electrode. This tool is designed to focus the electrolysis on the burrs. Depending on the part’s geometry and the severity of the burrs, the deburring process may be done manually or automatically.

Before starting the deburring procedure, it is necessary to choose the correct electrolyte. An ideal electrolyte consists of sodium chloride and sodium nitrate in water. Generally, the recommended concentration of these compounds is 0.7 Kg of sodium nitrate per 3 liters of water.

A 0.5-1 mm gap is required between the workpiece and the electrode for the best results. However, the distance can be varied depending on the part’s material.

Mechanical Deburring

Deburring is a standard manufacturing process. It removes burrs from metal parts. This can prevent them from malfunctioning. The deburring operation is an integrated part of the machining process.

There are many different methods used to deburr. They range from manual to robotic procedures. However, the most effective way is the one that is matched to the specifics of the component.

Manual deburring is commonly used in smaller shops. It is a time-consuming process. Fortunately, there are automated systems that eliminate the need for manual labor. These systems often have a tool changer that automatically inserts and removes the deburring tools.

A robotic deburring system is a much safer alternative. Rather than relying on a human operator, a robot can set up the workpieces in a specific manner and perform repetitive movements. Consequently, the cost and operating expense of this method are significantly reduced.

An electrochemical deburring procedure is particularly suitable for removing small burrs that are hard to reach. It uses an electrode that works with a sodium nitrate solution.

Tumbling

A deburring process involves removing stray metal fragments from a part. Depending on the type of machine, it can be done manually or with mechanized tools. Regardless of the method, several steps are involved. It can be a simple process or a very complex one.

Choosing the correct media is the key to a successful deburring process. The wrong media can lead to increased time, lowered quality and damage to the parts.

Fortunately, modern tumbling machines are very efficient and relatively inexpensive. They can produce smooth surfaces with minimal maintenance and help manufacturers save money. Using suitable tumbling media can also improve the life of your parts.

Tumbling processes have two primary forms, high-energy tumbling and vibratory tumble tumbling. Both have a similar objective, but the high-energy form is faster and produces exceptionally smooth and polished surfaces.

A processing table with a sludge tank is often used for smaller systems. Water is added to the media during the tumbling process to wash away any dirt and residue. Eventually, the sludge is pumped out of the tank with a sump pump.

Abrasive Flow Machining (AFM)

Abrasive flow machining (AFM) is a technology that is being increasingly used to finish surfaces. It is ideal for machining complex surfaces, including edges and internal shapes. The process uses abrasive-laden viscoelastic media, hydraulically or pneumatically extruded over a workpiece.

AFM has several advantages over traditional methods. These include the ability to process high-volume parts, low cost, and improved surface integrity.

AFM applies to various industries, particularly aerospace, medical, and precision dies. Several technical papers have been published on this technology. They are classified into four categories: abrasive media, applications, modeling, and optimization. This review paper provides an overview of these papers, paving the way for new research directions.

Abrasive flow machining is a technology that is especially effective for deburring and radiusing. It is also helpful in finishing complex internal passages. It produces deburr holes as small as 0.2 mm. Moreover, abrasive flow machining can increase the lifespan of parts.

An important factor in predicting the results of abrasive flow machining is the type of media used. Some techniques use viscous abrasives, while others use chemically inactive media.

Laser and High-definition Plasma Deburring

Laser and high-definition plasma deburring machines have a lot to offer in terms of productivity, accuracy and operating cost. The new technology is easier to learn than ever before. However, training is required before you can get the most out of the process.

Deburring is the process of smoothing rough edges on parts. It is essential for laser-cut details. This helps to prevent scraps from entering the eye or damaging the surface. Some features, such as plastic and acrylic, do not require post-processing. Other parts, such as brass, may be susceptible to scaling and oxidation.

A good deburring machine will give you the best results. Some devices use motorized deburring wheels. These wheels can be used in two ways. You can attach various deburr bits if you have a fixed deburring wheel setup. But if you have a rotating wheel, you will need to fit the machine with a series of fittings.

Another method of deburring is thermal deburring, also known as the thermal energy method. It involves feeding an accurately defined mixture of gases into a deburring chamber. During the process, sparks ignite the mixture. The resulting thermal burr is then removed in a relatively short period.