Deburring and finishing are vital processes that help to polish up the formed parts and eliminate any unwanted flaws and inadequacies on workpieces before processing or finishing them further.
With that said, this complete guide aims to shed more light on the above processes and look at some of the machines, such as angle grinders, that make these processes a success.
Basics Of Deburring
Deburring and finishing machines are purposely designed for removing faults that appear on workpieces after they have been produced.
These unwanted raised edges are commonly referred to as burrs, and they are categorized into two classes;
- Thermal burrs – these are dross or slag that results from heat-generating machines such as laser cutters
- Mechanical burrs– these often appear from operations such as stamping, shearing, or folding.
Some of the factors that contribute to the formation of these burrs include; the type of the metal, metal thickness, power, or pressure exerted by the machine, blade clearance, or condition of the die.
Deburring vs. Finishing
Deburring is the elimination of elevated edges or minor material pieces that remain on a piece of work after it has been produced.
On the other hand, finishing involves altering the workpiece surface to remove any pitting and scaling for enhanced quality or preparation for the next step, such as painting.
Finishing machines can also do other operations such as slag grinding, stock and calibration removal, and edge rounding.
Developing Deburring And Finishing Standards
The fabrication process is categorized into three stages;
- Design: This involves establishing a clear understanding of the quality expectations such as; removing all visible burrs, removing sharp edges, no deburring need, or round corners.
- Manufacturing: This includes the set of instructions to help operators understand the parameters for the task and also help to tailor their approach for the best results. Such guidelines include; equipment operation and calibration, specific job requirements, and deburring and finishing techniques.
- Inspection: This is an outline of how the finished products will be checked on whether they have met the requirement or standards needed. Examinations may include the use of visual, tactile, magnification, height gauge, or borescope techniques.
Benefits Of Automated Deburring And Finishing
There is a wide variety of debugging and finishing machines available in the market today to satisfy the needs of different individuals.
However, the automated deburring and finishing processes come with several benefits including;
- Enhanced consistency. The automation produced similar quality between operators hence limiting the amount of rework needed.
- Increased safety
- Provide more products
- Achieve higher quality finishes. Deburring using machines will produce better quality finishes.
Selecting The Proper Deburring And Finishing Machine
It is essential to consider several factors when searching for machines for your shop. Some of these include;
Wet Versus Dry
Dry machines are best suited to shops that grind similar materials consistently, for example, carbon steel. These machines are often cheap and need less maintenance.
However, if your shop grinds different types of metal materials regularly, you will require using a wet finishing or deburring machine.
These machines hence spray coolants to rinse the debris for a cooling effect and less heat production.
Regardless of the type of machine, you should regularly inspect tension levels, pinch roles bearings condition and make necessary replacements.
Picking the correct abrasive is significant to attaining the best performance of your machine. You should hence pay attention to factors such as type, grade, and abrasive mineral. Additionally, you will need to give into consideration the harsh styles including;
- Discs- these are ideal in handling sensitive and small parts such as galvanized or cladded materials.
- Belts- these operate on drums that continuously loop and mostly excel in removing vertical burrs.
- Brushes- brushes can get rid of the burrs without affecting surface coatings hence suitable in deburring small and delicate parts such as laser film or zinc.
Machine And Head Configuration
Most of the shops today prefer combination or multi-head machines that use different combinations of brushes, disks, and brushes, unlike in the past when most used single-head machines.
When considering the head configuration to satisfy your needs best, some of the factors to consider include; expected volume, machine uptime, needed throughput, number of passes, and desired grain finish.
Workpiece Quality And Characteristics
Some of the factors to consider here include the part size, coatings, type of material, and the finished quality.
We hope this guide has helped you understand metal deburring and finishing. However, if you are not sure about the type of deburring or finishing machine that’s best for your deburring and finishing needs, it advisable to consult a metal fabrication expert for assessment of your options.