Remove thorns or burrs that have formed around machined parts of the workpiece. The burr may seem small, but it directly affects the quality and precision of the product.
The Prevalence and Danger of Glitches
Burrs are an inevitable product of metal processing and are difficult to completely avoid. The existence of burrs not only affects the appearance of the product but also affects the assembly and performance of the product, accelerates the wear between the equipment, and reduces the service life. With the development of high technology and the improvement of product performance, the requirements for product quality are becoming more and more strict, and it is more and more important to remove the burrs of mechanical parts. The existence of burrs has an impact on product quality and product assembly, use, dimensional accuracy, and shape and position accuracy.
What is a Glitch?
The burr refers to a kind of excess iron filings generated on the edge of the product when the metal material is squeezed and deformed during the processing. They are formed during cutting, grinding, milling, and other similar chipping processes.
What is Deburring?
Metals are commonly machined using many processes to create sheets of specific shapes and sizes, which can be welded, molded, cast, trimmed, slit, or sheared. These procedures often create rough edges or protrusions. The raised particles and shavings machined from a metal blank are called "burrs," and the process by which they are removed is called deburring.
Abrasive substances may be applied, or metal can be wiped with a sticky cloth to remove thin cut pins and small notches, as well as abrasive sheets. Other methods require repeated submissions or the use of a shredder to smooth out nicks and fragments. Deburring and polishing of metal components in more than one part may be necessary. All surfaces must be completely smooth as burrs and chips can occur on seams and edges.
Deburring is very important to the quality, aesthetics, functionality, and smooth operation of the working part. Equally important for safety, because even small notches can cause moving parts to catch, creating potential accidents, injuries, or unnecessary production delays.
What are the Methods of Deburring?
Contains chemical removal and physical removal.
- Electrolytic deburring:
This is to use electrical energy and chemical energy to dissolve the anode to remove burrs. The part is connected to the positive pole of the DC power supply as the anode, the forming tool is connected to the negative pole of the DC power supply as the cathode, and a certain gap is maintained between the two poles to allow the electrolyte to circulate. When the anode and the cathode are immersed in the solution and supplied with direct current, an electrochemical reaction occurs on the surface of the anode. The dissolved metal on the surface of the part and the electrolyte forms a viscous liquid concentrated in the low recesses on the surface of the part, with high resistance and corrosion. The burr protrudes from the surface of the part. Under the influence of the temperature difference, the liquid film is difficult to form. After the power line is highly concentrated in the burr part, the burr closest to the cathode will dissolve at the fastest speed until all the burrs are dissolved, and the edges gradually form rounded corners, that is, achieve the purpose of deburring.
This method is suitable for non-ferrous and ferrous metal parts, especially for parts with complex shapes and inner holes, cross holes, and burrs on inner surfaces that are difficult to remove by mechanical and manual methods. burrs on parts.
- Chemical deburring:
Put the cleaned metal parts into a chemical solution (50°C), and the metal on the surface of the parts will be transferred to the solution in the form of ions. These ions gather on the surface of the workpiece and form a mucus film with high resistance and low conductivity through a chemical reaction, which protects the surface of the workpiece from corrosion, and the burr protrudes from the surface, and the chemical action will remove the burr. When machining, only one groove is required. Depending on the deburring workpiece material, different chemical solutions are used. The main components of the base can be prepared in proportions such as hydrochloric acid, phosphoric acid, sulfuric acid, diphenylamine hydrochloride, and water. Chemical deburring is suitable for small metal parts and can remove fine burrs less than 0.07 mm thick.
- High temperature deburring:
The parts that need to be deburred are placed in a tightly sealed chamber, and then a hydrogen-oxygen mixture of a certain pressure is fed. After the spark plug is ignited, the mixture explodes instantaneously, releasing a lot of heat, and the instantaneous temperature is as high as 3 300 ℃ or more. Due to the extremely short explosion time, the burrs of the parts are burned away, and other parts of the parts have no time to change. During the explosion, the high-pressure gas is pervasive, and the burrs of all inner holes, cross holes, grooves, deep holes, etc. of the parts can be burned off. A special high-temperature deburring tool is required. This method of deburring is suitable for metal, plastic, and rubber parts of any structural shape, especially parts with complex shapes that are difficult to remove burrs by hand.
- Rolling and deburring:
Put a certain proportion of the workpiece and the abrasive into the closed drum. During the rotation of the drum, grinding occurs between the parts and the abrasive and the parts to remove burrs. There are special deburring machines and centrifugal rolling polishing machines for rolling and deburring equipment. Abrasives can be quartz sand, sawdust, alumina, ceramics, dolomite, silicon carbide, metal rings, etc. Choose according to the material, shape, and size of the part, as well as the location and size of the burr. With this method, the deformation of the parts is small, the equipment is simple, the operation is easy, and the sources of abrasives are wide, but the large burrs are difficult to remove.
- Floating deburring spindle for deburring:
The floating deburring spindle is installed on the manipulator or the tool machining center, and the spindle is automatically replaced through the quick-change interface to realize multi-process processing. The main application fields include deburring of cylinder heads, crankshafts and connecting rods of automobile engine blocks, grinding and deburring of wheel hubs, deburring of gas turbine blades, deburring of gears, grinding and polishing of welding seams, deburring of casting parting lines, ceramic tiles, sanitary ware, and sanitary ware. Grinding and polishing, glass edge passivation, mold polishing, mobile phone shell deburring, polishing, and other industries.
This method avoids the time-consuming and laborious manual grinding and deburring, realize a high degree of automation, and greatly improves efficiency and accuracy. It saves a lot of labor costs and reduces the failure rate of parts caused by manual operation errors. Using a floating mechanism, the tool will automatically offset radially or axially according to the actual shape of the workpiece, ensuring a beautiful and consistent deburring effect on the workpiece, avoiding the uneven deburring of the rigid spindle and the trouble of complex programming.
Applications of Deburring:
Deburring workpieces, especially thin workpieces, and edges of workpieces. Also includes surface grinding of pipes, connections, and shafts. Burrs that appear in the inner hole during punching or laser processing can be removed with an abrasive brush. Precision metal parts for automobiles keep multiple edges free of burrs and are ground on uneven surfaces.