Glitch---The people who have struggled in the metal industry must be familiar with it. In the process of metal products processing, it is ubiquitous. No matter how advanced and sophisticated equipment you use, it will be born with the product. The so-called burr is mainly a kind of extra iron scrap generated by the plastic deformation of the material and processed at the edge of the processed material, especially the material with good ductility or toughness, which is particularly prone to burrs, and the burr problem is the metal processing industry. One of the challenges that engineers have not been able to solve so far.
The types of burrs in metal processing mainly include flash burrs, sharp burrs, splashes and the like, and a prominent excess metal residue that does not meet the design requirements of the product. For this problem, there is no effective method to eliminate it in the production process so far, so in order to ensure the design requirements of the products, engineers only have to work on the removal of the latter, so far different products are different. There are many methods and equipment for removing burrs.
In general, the method of removing burrs can be divided into four categories.The coarse grade (hard contact) belongs to this category of cutting, grinding, boring and scraping.
Ordinary grade (soft touch): This category is abrasive belt grinding, grinding, elastic grinding and polishing.
Precision grade (flexible contact): This category includes processing, electrochemical machining, electrolytic grinding and rolling.
Ultra-precision (precise contact): This type of deburring method, such as abrasive flow deburring, magnetic grinding deburring, electrolytic deburring, thermal deburring, and dense radium ultrasonic deburring, etc. Part processing accuracy.When we choose the deburring method, we should consider various factors, such as the material properties of the part, the shape of the part, the size and precision of the part, especially the changes of surface roughness, dimensional tolerance, deformation and residual stress.
Electrolytic deburring is a chemical deburring method that removes burrs from machining, grinding, and stamping, and rounds or chamfers the edges of metal parts.
An electrolytic processing method for removing burrs of metal parts by electrolysis, referred to as ECD in English. Place the tool cathode (usually brass) in the vicinity of the burr of the workpiece, with a certain gap (usually 0.3 to 1 mm). The conductive portion of the tool cathode is aligned with the burr edge, and the other surfaces are covered with an insulating layer to concentrate the electrolysis on the burr portion. When processing, the tool is connected to the cathode of the DC power supply, and the workpiece is connected to the positive pole of the DC power supply. A low pressure electrolyte (usually sodium nitrate or sodium chlorate solution) with a pressure of 0.1 to 0.3 MPa flows between the workpiece and the cathode. When the DC power is turned on, the burr is dissolved and removed, and is carried away by the electrolyte.
The electrolyte is corrosive, and the workpiece should be cleaned and rust-proofed after deburring. Electrolytic deburring is suitable for removing burrs of cross-holes or complex-shaped parts in hidden parts of parts, and the production efficiency is high. The deburring time generally takes only a few seconds to several tens of seconds. This method is commonly used for deburring of gears, splines, connecting rods, valve bodies and crankshaft oil passage orifices, as well as rounding of sharp corners. The disadvantage is that the vicinity of the burr of the part is also subjected to electrolysis, and the surface will lose its original luster and even affect the dimensional accuracy.
Of course, in addition to electrolytic deburring, there are several special methods for deburring:
First, the abrasive flow deburring
Abrasive Flow Processing Technology (AFM) is a new deburring process developed in the late 1970s. This process is especially suitable for burrs that have just entered the finishing stage, but for small and long holes and metal molds that are not accessible at the bottom. It is not suitable for processing.
Second, magnetic grinding deburring
This method originated in the former Soviet Union, Bulgaria and other Eastern European countries in the 1960s. In the mid-1980s, the Japanese car made an in-depth study of its mechanism and application.
During the magnetic grinding, the workpiece is placed in the magnetic field formed by the two magnetic poles, and the magnetic abrasive is placed in the gap between the workpiece and the magnetic pole. The abrasive is aligned along the magnetic field line under the action of the magnetic field force to form a soft and rigid magnetic grinding. Brush, when the workpiece rotates in the magnetic field for axial vibration, the workpiece and the abrasive move relative to each other, the abrasive brush grinds the surface of the workpiece; the magnetic grinding method can grind and deburr the parts efficiently and quickly, suitable for Various materials, various sizes, and various structural parts are a kind of finishing method with low investment, high efficiency, wide application and good quality. At present, foreign countries have been able to grind and deburr the rotating inner and outer surfaces, flat parts, gear teeth, complex surfaces, etc., remove the oxide scale on the wire and wire, and clean the printed circuit board.
Third, thermal deburring
Thermal deburring (TED) is the burning of burrs by the high temperature generated by the deflagration of a mixture of hydrogen-oxygen gas or oxygen and natural gas. Oxygen and oxygen or natural gas and oxygen are introduced into a closed container, and the spark plug ignites, so that the mixture detonates in a moment to release a large amount of heat energy to remove the burr. However, after the workpiece is burned and burned, its oxidized powder adheres to the surface of the workpiece and must be cleaned or pickled.
Fourth, dense radium strong ultrasonic deburring
Ultra-violet ultrasonic deburring technology is a deburring method that has been popular in recent years. The cleaning efficiency is only 10 to 20 times that of ordinary ultrasonic cleaning machines. The holes are evenly covered in the water tank, so that the ultrasonic waves do not need to be cleaned. The agent can be completed simultaneously in 5 to 15 minutes.
Metal processing has compiled 10 of the most common deburring methods for everyone:
1, manual deburring
This is also a common method used by general enterprises, using sickles, sandpaper, grinding heads, etc. as auxiliary tools. The file has a manual file and a pneumatic shift.
Brief comment:
Labor costs are expensive, efficiency is not very high, and complex cross holes are difficult to remove.
The technical requirements for workers are not very high, and products with small burrs and simple product structure are suitable.2, die deburring
The deburring is performed by using a punching die and a punching machine.
Brief comment:
A certain die (rough die + fine die) production cost is required, and it may be necessary to make a shaping die.
Suitable for products with simple parting surface, efficiency and deburring effect is better than manual.3, grinding deburring
Such deburring includes vibration, sand blasting, rollerting, etc. Currently, enterprises use more.
Brief comment:
There is a problem that the removal is not very clean, and it may be necessary to manually process the residual burrs or to deburr other ways.
Suitable for small products with large batch sizes.4, frozen deburring
The burrs are quickly embrittled by cooling, and then the projectile is sprayed to remove the burrs.
Brief comment:
The price of equipment is about 200,000 and 300,000;
Suitable for products with small wall thickness and small product.5, hot deburring
Also called heat to deburring, exploding to deburring. By passing some of the easy gas into a furnace of the equipment, and then through some medium and conditions, the gas is instantaneously exploded, and the energy generated by the explosion is used to dissolve and remove the burr.
Brief comment:
Expensive equipment (up to millions of prices), high technical requirements, low efficiency, side effects (rust, deformation);
Mainly used in some high-precision parts and components, such as automotive and aerospace precision parts.6, engraving machine deburring
Brief comment:
The price of the equipment is not very expensive (tens of thousands), it is suitable for the simple spatial structure, and the required deburring position is simple and regular.7, chemical deburring
Using the principle of electrochemical reaction, the deburring operation is automatically and selectively performed on the parts made of the metal material.
Brief comment:
Suitable for internal burrs that are difficult to remove, suitable for small burrs (thickness less than 7 filaments) for pump bodies, valve bodies, etc.8, electrolytic deburring
An electrolytic processing method for removing burrs of metal parts by electrolysis.
Brief comment:
The electrolyte is corrosive, and the vicinity of the burr of the part is also subjected to electrolysis. The surface will lose its original luster and even affect the dimensional accuracy. After the workpiece is deburred, it should be cleaned and rust-proofed.
Electrolytic deburring is suitable for removing burrs of cross-holes or complex-shaped parts in hidden parts of parts, and the production efficiency is high. The deburring time generally takes only a few seconds to several tens of seconds.
It is suitable for deburring of gears, connecting rods, valve bodies and crankshaft oil passage orifices, as well as rounding of sharp corners.9, high pressure water jet deburring
Using water as the medium, it uses its instantaneous impact force to remove the burrs and flashes produced after processing, and at the same time achieve the purpose of cleaning.
Brief comment:
The equipment is expensive and is mainly used for the heart part of the car and the hydraulic control system of the construction machinery.10, ultrasonic deburring
Ultrasonic waves produce an instantaneous high pressure to remove burrs.
Brief comment:
Mainly for some microscopic burrs, generally if the burr needs to be observed with a microscope, you can try to remove it by ultrasonic method.
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