Before we can dive into the details of the deburring process, it is important to understand what a burr is and how it affects the quality of your metal parts.<\/p>\n
![\"burred](\"https:\/\/fractory.com\/wp-content\/uploads\/2019\/05\/burr-vs-deburr.jpg\")
In the context of metal manufacturing, a burr refers to the formation of rough edges or ridges on the metal piece. The reason behind it lies in the manufacturing process and the tools involved in its production. It is especially common with cutting operations on sheet metal<\/a>.<\/p>\n
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- Reduced safety. Sharp metal edges result in hazardous handling for operators.<\/li>\n
- Increased stress during operation. This results in a reduction of resistance to fractures and fatigue.<\/li>\n
- Susceptibility to corrosion<\/a>. Related to a difference in material thickness.<\/li>\n
- Lubrication problems, especially because of contamination with burr scraps, and wear at interfaces.<\/li>\n
- Interference when applying finishing processes like powder coating or electroplating<\/a>.<\/li>\n<\/ul>\n
Clearly, the formation of burr should be avoided whenever possible. But as a “side-product” of many manufacturing methods, it is often unavoidable. In those instances, deburring is necessary.<\/p>\n
Which Manufacturing Methods Leave a Burr?<\/h2>\n
Burr commonly occurs when producing sheet metal parts using different manufacturing methods. Those include machining and cutting processes.<\/p>\n
Some of the most common burr-leaving machining processes are:<\/p>\n
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- Milling<\/a><\/li>\n
- Drilling<\/li>\n
- Engraving<\/li>\n
- Turning<\/a><\/li>\n<\/ul>\n
Cutting processes used with sheet metal that leave burrs include:<\/p>\n
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- Laser cutting<\/li>\n
- Plasma cutting<\/a><\/li>\n
- Punching<\/a><\/li>\n
- Shearing<\/li>\n
- Blanking<\/a><\/li>\n<\/ul>\n
It is important to note that there are factors that relate to burr formation. Therefore, not every one of those cutting methods leaves a burr. At least not always.<\/p>\n
These factors are related to many things. The most important is probably the awareness and skills of the machine operator handling the parts and configuring the machinery. Also, a lot comes down to the material thickness and grade. Some materials are a lot easier to cut while leaving a satisfactory result without the need for post-processing.<\/p>\n
Nevertheless, it is possible to remove burrs to achieve a smooth surface. And there are many different deburring methods to choose from. Each of them comes with advantages and disadvantages.<\/p>\n
Deburring Methods and Tools<\/h2>\n
Looking deeper into the subject, it is clear that there is a plethora of deburring options available. The Deburring and Edge Finishing Handbook by Laroux K Gillespie<\/a> tells us that there are more than 80 different processes currently in use in metal manufacturing.<\/p>\n
With that said, we list the main methods for deburring metal parts for a smooth finish.<\/p>\n
Manual Deburring<\/h3>\n
This is the oldest and most basic method to eliminate burr. It requires a skilful craftsman to guarantee the best results. Therefore, it is a method that takes a lot of time and effort.<\/p>\n
As a time-consuming technique, manual deburring is nowadays mostly used in small shops with a low production rate. Cleaning large batches is not cost-effective but having the required skills in the workshop may come in handy.<\/p>\n
![\"Manual](\"https:\/\/fractory.com\/wp-content\/uploads\/2019\/10\/Manual-deburring.jpg\")
<\/p>\nCommon tools used to apply this method<\/a> include deburring knives, files, sandpapers and other polishing tools.<\/p>\n
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- Flexible<\/li>\n
- Does not require expensive machines or tools<\/li>\n<\/ul>\n
Cons:<\/p>\n
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- Only suitable for small quantities<\/li>\n
- Only suitable for small burrs and simple structures<\/li>\n
- Not cost-effective, especially with large batches<\/li>\n<\/ul>\n
Punch Deburring<\/h3>\n
This method uses a punching machine to eliminate the burr. It requires different types of dies to achieve what is called punch mould work, including rough blanking dies, fine blanking dies, and sizing dies.<\/p>\n
Pros:<\/p>\n
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- Higher productivity compared to manual deburring<\/li>\n
- Better efficiency than manual deburring<\/li>\n<\/ul>\n
Cons:<\/p>\n
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- Does not work with complex structures<\/li>\n
- Requires special tools<\/li>\n<\/ul>\n \n\n Scale Your Manufacturing from Prototyping to Series<\/span>\n\n
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Hole Deburring<\/h3>\n
As the name suggests, this method is used when deburring is needed on the inner part of a hole. There are a variety of tools to apply this method available in the current market, but they usually have the same configuration.<\/p>\n
A cutting tool is spring-loaded and mounted on a spindle. This tool is positioned so that it can go through the hole smoothly and comes out by touching the surface with the edge that cuts the burr without causing any type of scratches or damages. Some of the cutting tools come with a tapered end that allows the creation of a chamfer at the front of the hole when entering.<\/p>\n
Pros:<\/p>\n
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- Fast and cost-effective<\/li>\n
- Suitable for many pieces<\/li>\n
- Good surface finishes<\/li>\n<\/ul>\n
Cons:<\/p>\n
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- Only applicable on holes<\/li>\n
- Requires special tools<\/li>\n<\/ul>\n
Brushing<\/h3>\n
Considering the name of the method, it is easy to deduce that, in this case, the burr is eliminated by \u201ccleaning\u201d the surface with a special type of brush.<\/p>\n
The method works in a similar way to manually deburring with sandpaper and similar tools. The deburring brushes are usually made of abrasive materials with a specific grit number.<\/p>\n
The main difference is that most of these brushes are designed to be mounted on machine tools, making the process more efficient and giving the possibility of automating this manufacturing step too.<\/p>\n
![\"Automated](\"https:\/\/fractory.com\/wp-content\/uploads\/2019\/10\/Brush-Deburring.jpg\")
Brushes eliminate sharp edges<\/figcaption><\/figure>\n Pros:<\/p>\n
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- Fast and cost-effective<\/li>\n
- Applicable to complex pieces with many different features like in the case of a crankshaft<\/li>\n
- Possible to automate<\/li>\n
- Brushes are not very expensive compared to other tools<\/li>\n<\/ul>\n
Cons:<\/p>\n
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- More than one brush may be needed<\/li>\n
- A tool changer must be available for increased efficiency<\/li>\n<\/ul>\n
Electrochemical Deburring<\/h3>\n
This method, also referred to as electropolishing<\/a>, is commonly used on small metal parts with a burr in areas that cannot be reached by other deburring methods. It is basically the reverse operation of plating. Instead of adding material, electrochemical deburring eliminates it.<\/p>\n