Burrs are a headache. Normal processing procedures will form sharp edges and burrs on the surface of the workpiece. The presence of burrs will increase the risk of personal injury, endanger product quality, affect equipment use, and even shorten equipment life. However, the cost of deburring is not low. According to statistics, in the processing of precision parts, the cost of deburring accounts for about 10% to 25%. If the precision parts have deep holes and grooves, the cost of deburring will increase greatly. As Precision Machining penetrates more and more industries in modern industrial manufacturing, deburring has increasingly become a key process integrated into precision machining. Today we will take a look at what advanced deburring technologies are available on the market.
Commonly used deburring methods include electrolytic deburring, abrasive flow deburring, magnetic abrasive deburring, thermal deburring, powerful ultrasonic deburring, high-pressure water jet deburring, and liquid nitrogen freezing deburring, etc., often combined with automated system operations. For the surface deburring treatment of workpieces of different materials, the usage scenarios, methods, solvents/abrasives are different.
Electrolytic deburring
Electrolytic deburring (ECD) is a chemical deburring method. It uses electric energy and chemical energy to dissolve and deburr the anode. The parts are connected to the positive pole of the DC power supply, called the anode, and the forming tool is connected to the negative pole of the DC power supply. Called the cathode. Keep a certain gap between the two poles to allow the circulating electrolyte to flow. When the anode and cathode are immersed in the solution and connected to direct current, as the surface of the anode undergoes an electrochemical reaction, the surface of the part forms a layer of viscous liquid due to the dissolved metal and the electrolyte. Concentrated in the low recesses on the surface of the part, this viscous liquid has a higher electrical resistance and a lower electrical conductivity. It can protect the surface of the parts from corrosion or less corrosion, and the burrs protrude on the surface of the parts. Under the influence of temperature and humidity differences, the liquid film is difficult to form. Therefore, the power line is highly concentrated on the deburring part after power on, and the burr closest to the cathode will be Dissolve at the fastest speed until the burrs are completely dissolved and the edges gradually form rounded corners to achieve the purpose of deburring. This method is often used for deburring gears, splines, connecting rods, valve bodies and crankshaft oil passages, as well as rounding sharp corners.
Electrolytic deburring can effectively remove burrs of any size, such as cross holes in hidden parts of parts or burrs on parts with complex shapes. The production efficiency is high, and the deburring time generally only takes a few seconds to tens of seconds. Therefore, the operation is very simple, the productivity is high, and it is suitable for automated processing. In the process, no thermal stress and mechanical stress are generated, and the workpiece will not be deformed. The applicable range of materials and hardness is wide. But there are also disadvantages. First, the electrolyte is corrosive, and the workpiece should be cleaned and rust-proof after deburring; the second part is also subjected to electrolysis near the burr, and the surface will lose its original luster and even affect the dimensional accuracy.
Deburring by abrasive flow
Abrasive flow deburring refers to an extrusion method whose abrasive has fluidity, and the particles in it continuously grind the surface of the workpiece to complete polishing and deburring. Also known as fluid polishing, or extrusion grinding and polishing, it is mainly for inner holes, micro holes, irregular shapes, spherical surfaces, gears, etc. It is known for its high efficiency, thorough polishing and deburring, and no damage to the workpiece. Simply put, it is the process of polishing and deburring through semi-fluid media, which is mainly for inner holes and small and medium-sized workpieces with irregular shapes.
Magnetic grinding and deburring
Magnetic grinding and deburring, clever application of magnetic field force to achieve super electromagnetic force, conducts small grinding stainless steel needles (reusable), produces high-speed jumping flow, turns and other actions, rubs on the surface of the inner hole, dead corner, and gap of the workpiece, one-time Efficiently achieve precise grinding effects such as polishing, cleaning and removing burrs. It can be used for finishing jewelry crafts, hard plastics, plastics, automatic lathe parts,
Cnc Machined Parts, die-casting, stamping parts, springs, shrapnel parts, electronics, communications, fasteners, precision hardware parts, etc.
The magnetic grinding deburring method has the following advantages: it can finish the surface of the workpiece while removing the burrs. Compared with the grinding process, the surface finish of the workpiece after the magnetic grinding process can be improved by about one level; it is suitable for various precision parts. Deburring and polishing can remove dirt, remove burrs, and improve the surface brightness of the product; the "polishing brush" formed by magnetic abrasives can evenly reach the surface of complex shapes, so the inner and outer surfaces of the workpiece can be ground at the same time. Small hardware, small accessories and other dead corners, the inner hole treatment effect is excellent.
Thermal deburring
Thermal deburring is a process that uses thermochemical reactions to deburr. Put the parts in a sealed working chamber, and then fill it with a certain amount of methane gas (CH4) or gas and oxygen (O2) mixed gas. After being ignited by the spark plug, the mixed gas reacts in an instant, releasing a lot of heat, making the burr at high temperature (About 3000℃), high pressure (20 times the inflation pressure), high speed (8 times the speed of sound), heating and spontaneous combustion to achieve the purpose of deburring. Due to the extremely short reaction time (only 0.003 seconds), the original size, surface finish, metallographic structure and mechanical properties of the processed parts are basically unchanged.
The magnetic grinding deburring method has the following advantages: it can finish the surface of the workpiece while removing the burrs. Compared with the grinding process, the surface finish of the workpiece after the magnetic grinding process can be improved by about one level; it is suitable for various precision parts. Deburring and polishing can remove dirt, remove burrs, and improve the surface brightness of the product; the "polishing brush" formed by magnetic abrasives can evenly reach the surface of complex shapes, so the inner and outer surfaces of the workpiece can be ground at the same time. Small hardware, small accessories and other dead corners, the inner hole treatment effect is excellent.
Thermal deburring
Compared with the base of the part, the burr or flash has a large surface area and a small volume, which absorbs more heat. Also, because the roots of the burrs or flashes are thin and thin, this hinders the heat transfer to the part matrix, and the reaction time is extremely short, so only the burrs and flashes can be sintered and removed, and the area-to-volume ratio of the part matrix is relatively small, so The base material of the part will not be burnt, and the size, hardness and metallographic structure of the part will not change. Because the gas has good accessibility and no holes, it has a unique removal effect on parts with complicated shapes or difficult to remove burrs by hand, such as inner holes, cross hole grooves, blind holes and other parts. The equipment is small in size, high in efficiency (90 seconds per cycle), and good in deburring. It can meet the needs of mass production and is widely used in machinery, hydraulics, pneumatics, die-casting, automobiles, aviation and other fields.
Powerful ultrasonic deburring
Ultrasonic deburring uses vacuum (cavity for short) generated by strong ultrasonic waves in the liquid, and then uses the impact force of the high-pressure water flow when the cavity is generated and disappeared for deburring. The strong ultrasonic unit strength (power per square centimeter) of the powerful ultrasonic deburring technology is 10-20 times that of the ordinary ultrasonic cleaning machine. The cavities are evenly distributed in the sink, and the batch parts can be finished in 5-10 minutes at the same time. Deburring and improve cleanliness. Suitable for metal types including stainless steel, various aluminum alloys and other various metals; small gears, motor cores, aluminum precision processing products, etc.; automobile valve bodies, hydraulic machine shafts, gears, most computer parts, aluminum alloys, Rocker arms, precision screws, etc.
High-pressure water jet deburring
High-pressure water jet deburring is the use of a special pump to pressurize water or water-soluble oil, and then spray it from a specially designed nozzle in a certain shape, such as a fan, cone, etc., to generate huge impact energy to impact the parts. The purpose of removing burrs. This method can effectively remove the burrs, chips and oil impurities of the cross holes, oblique holes, threaded holes and blind holes inside the parts, and it is especially suitable for a variety of burrs formed after machining of complex parts. Since the medium is water, it will not pollute the environment, but attention must be paid to rust prevention. It is suitable for the deburring and cleaning of various ductile iron, gray cast iron, powder metallurgy, cast aluminum alloy, zinc alloy, stainless steel parts such as automobile engines, gearboxes, refrigeration compressors, ships, aircraft engines, military products, molds, etc.
Liquid nitrogen freezing deburring
Liquid nitrogen freezing deburring is mainly for the deburring technology of rubber and plastic polymer materials. After molding, the flash of the rubber and plastic products is usually thinner than the product, and at low temperature, it will embrittle before the product. The freezing deburring machine uses this principle. In the time difference area where the flash is embrittled and the product itself is still elastic, the high-speed injection of plastic pellets is used to impact the product, so that the brittle flash can be completely removed. Since the temperature of the flash burr decreases faster than the product itself, the burr can be removed without damaging the product itself. Suitable for complex rubber parts, precision seals, oil seals, automotive rubber parts, micro aerospace parts, precision plastic parts, precision artificial rubber parts, complex electronic parts, microelectronic parts, zinc, magnesium, and aluminum die castings.
