Burrs are a common problem in metal processing, such as drilling, turning, milling, sheet metal cutting, etc.
Aluminum alloy burr phenomenon is unavoidable, at present there are many kinds of methods in the process of dealing with burrs. In the die casting production process, due to the pressure impact and clamping force is insufficient and other factors, die casting produce burr is inevitable. In recent years with the quality requirements of die casting parts increasingly improve, the requirements of the burr is also more stringent, at the same time, deburring methods are also endless. Deburring process is the most people's headache, the following is all kinds of die casting deburring method of advantages and disadvantages of the review, can let you understand more about all kinds of deburring method, and according to their own needs to choose the suitable deburring method.
1, manual deburring
This is the most traditional die-casting plant commonly used way, using files (files have artificial files and pneumatic files), sandpaper, belt sander, grinding head as an auxiliary tool.
Disadvantages: labor costs are more expensive, the efficiency is not very high, and it is difficult to remove the complex cross-holes.
Applicable object: the technical requirements of workers are not very high, applicable to small burrs, simple product structure of aluminum alloy die casting.
2, die deburring using the production of die with the punch for deburring.
Disadvantages: need a certain amount of die (rough die + fine punch die) production costs, may also need to make plastic mold.
Applicable objects: suitable for parting surface is relatively simple aluminum alloy die casting, efficiency and deburring effect is better than manual.
3、Grinding deburring
This kind of deburring contains vibration, sand blasting, roller and other ways, at present the die casting factory adopts more.
Disadvantages: there is not very clean removal of the problem, may need to follow up manual processing residual burrs or with other ways to deburr.
Applicable object: suitable for large batch of small aluminum alloy die casting.
4, freezing deburring
The use of cooling to make the burr quickly embrittled, and then spray projectiles to remove the burr. Equipment price is about two or three hundred thousand;
Applicable objects: suitable for burr wall thickness is small and the volume is also small aluminum alloy die casting.
5, heat explosion deburring
Also called thermal deburring, explosion deburring. Through some flammable gas, through to a device furnace, and then through some media and conditions of the role of the gas instantaneous explosion, the use of energy generated by the explosion to dissolve the removal of burrs.
Disadvantages: expensive equipment (millions of prices), high operational requirements, low efficiency, side effects (rust, deformation);
Applicable objects: mainly used in some high-precision parts and components in the field, such as automotive aerospace and other precision parts.
6, engraving machine deburring
Equipment is not very expensive (tens of thousands).
Applicable objects: applicable to the space structure is simple, the required deburring position is simple and regular.
7, chemical deburring
With the principle of electrochemical reaction, the parts made of metal materials automatically, selectively complete deburring operations.
Applicable objects: for difficult to remove the internal burr, suitable for pump body, valve body and other products fine burr (thickness less than 7 silk).
8、Electrolysis deburring
The use of electrolysis to remove aluminum alloy die casting burrs an electrolytic processing method. Electrolysis deburring is suitable for removing aluminum alloy die casting hidden parts of the cross-hole or the shape of the complex parts of the burr, high production efficiency, deburring time is generally only a few seconds to tens of seconds.
Disadvantages: electrolytic solution has a certain degree of corrosiveness, parts burr near the electrolytic effect, the surface will lose its original luster, and even affect the dimensional accuracy, aluminum alloy die casting deburring should be cleaned and rust treatment.
Applicable objects: applicable to gears, connecting rods, valve body and crankshaft oil orifice deburring, as well as chamfering sharp corners.
9, high-pressure water jet deburring
Water as a medium, the use of its instantaneous impact to remove burrs and flying edges generated after processing, while the purpose of cleaning can be achieved.
Disadvantages: expensive equipment
Applicable objects: mainly used in the heart of the car and engineering machinery hydraulic control system.
10, ultrasonic deburring
Ultrasonic waves produce instantaneous high-pressure burr removal.
Applicable objects: mainly for some microscopic burrs, generally if the burr needs to be observed with a microscope, then you can try to remove the ultrasonic method.
11, abrasive flow deburring
Conventional vibration grinding, for the hole type of burr is difficult to cope with, the typical abrasive flow processing technology (two-way flow), through the two perpendicular to the opposite abrasive cylinder to promote the abrasive so that it is in the workpiece and the fixture formed by the channel flow back and forth. The abrasive enters and flows through any area through which it is confined to produce an abrasive effect. Extrusion pressure is controlled from 7-200 bar (100-3000 psi) for different strokes and different number of cycles.
Applicable objects: can deal with 0.35mm microporous burr, no secondary burr generation, fluid characteristics can deal with complex position burr.
12、Magnetic deburring
Magnetic grinding process is under the action of a strong magnetic field, filled in the magnetic field of magnetic abrasives are arranged along the direction of the magnetic lines of force, adsorbed in the magnetic pole to form “abrasive brushes”, and on the surface of the workpiece to produce a certain amount of pressure, the magnetic pole in the drive “abrasive brushes” rotating At the same time, the magnetic pole drives the “abrasive brush” to rotate and keep a certain gap to move along the surface of the workpiece, so as to realize the finishing processing of the surface of the workpiece.
Characteristics: low cost, wide range of processing, easy to operate
Process elements: grinding stone, magnetic field strength, workpiece speed, etc.
13、Robot sanding
The principle of the unit is similar to manual deburring, only the power into a robot. Programming technology and force control technology to support the realization of flexible grinding (pressure and speed of change), robot deburring advantages.
To summarize small quantities/large sizes: manual or scraper processing. Complex structure/mass production: vibratory grinding or tumbling. High precision requirements: laser or electrolytic deburring. Internal Cavity Burr: Heat Blast or High Pressure Water Jet. Cost sensitive: sandblasting or chemical deburring.
Precautions: - Aluminum alloys are soft, avoid over-grinding which may lead to dimensional deviations. - Chemical/electrolytic methods require controlled parameters to prevent corrosion of the substrate. - Thermal methods need to assess the risk of distortion and do post-treatment (e.g. sandblasting, anodizing) if necessary.
