What are Metal Burrs and How to Remove It?

How are metal burrs formed?

Common Manufacturing Processes Leading to Burr Formation

Understanding the origins of metal burrs in our quest to manufacture precision sheet metal components at Shengen is crucial. A variety of manufacturing processes causes these protrusions. Each has its unique challenges. We’ll look at some of the common causes.

Machining

Machining processes like milling, turning, and drilling often form metal burr. Cutting tools often leave behind tiny, irregular edges or spikes when they cut metal. The type of tool, its sharpness, and the speed of operation can affect the burrs produced.

Sheet Metal Operations

Burrs are especially common in sheet metal operations such as punching, laser cutting, and shearing. The force used to cut or shape metal sheets can cause the material to be displaced, resulting in burrs.

Grinding and Finishing Processes

Even refining or finishing processes, such as grinding, can introduce burrs. When abrasive material wears away the metal surface, it can tear instead of cut, causing micro-burrs.

The materials: Susceptibility of burrs

Due to their malleability, soft metals like aluminum and copper are more susceptible to the formation of burrs. The pressure from cutting or shaping tools easily deforms the materials. This leads to a more significant number of burrs. While harder metals such as steel and titanium are not immune to burrs, they may produce smaller protrusions that are easier to handle.

Metal Burrs: What are the Implications?

Metal burrs are small but can have a significant impact on sheet metal fabrication. We’ll explore the many ways that metal burrs impact our safety, quality, and performance.

Safety Concerns

Injury Risks and Prevention Measures

Metal burrs can cause injury. These sharp edges are capable of cutting skin and causing severe injuries or cuts to those who handle the parts. We prioritize safety in our facilities by using strict handling protocols and protective gear like gloves.

Quality and Performance

Impact on product functionality

Burrs are a significant factor in the performance of a product. Even a tiny protrusion in a part can cause it not to fit together perfectly. It can cause equipment to malfunction or, in aerospace and automotive safety applications, pose a significant risk.

Aesthetic considerations

Burrs are not only functional but can also affect the aesthetic value of a product. Burrs are detrimental in industries that place a high value on the appearance and finish of components, like consumer electronics or exterior trims for automobiles. Our parts are polished and buffed to make them visually appealing and functional.

Economic Repercussions

Poor Burr Management Costs

If not adequately managed, burrs can lead to serious economic consequences. Reworking or scrapping parts because of excessive burrs can increase production costs, waste valuable materials and labor, and lead to increased costs.

Losses of Efficiency in Production

A lack of efficiency in metal burr removal can lead to production bottlenecks and a reduction in overall manufacturing efficiency. Our investment in deburring technology and staff training allows us to keep up production rates without compromising the quality of parts.

Deburring Tools and Methods

Looking deeper into manufacturing, you will find many deburring techniques available to achieve a smooth finish on metal parts.

The processes used range from manual to fully automated, showing a broad spectrum of methods. The versatility of deburring techniques allows manufacturers to choose between thermal and mechanical methods.

Let’s look at the most common deburring techniques to achieve a seamless finish on metal parts.

Manual Deburring

Manual deburring is traditional, but it requires skilled craftsmanship to achieve optimal results. This makes it a time-consuming and labor-intensive process. While effective for small-scale operations, this method is not practical for large batches because of its inefficiency.

Manual deburring with a file

Using this method with deburring tools, files, sandpapers, and other polishing instruments is best. This technique’s flexibility and its minimal requirement for expensive machinery stand out.

Pros:

• Highly Flexible
• No need to purchase expensive equipment

Cons:

• Impractical for large quantities
• Limitations to simple parts and small burrs
• Cost-effective only for small quantities

Punch Deburring

This technique uses a punching device to use various dies, such as rough and fin blanking dies and sizing dies. It is more efficient and productive than manual methods.

Pros:

• More productive than manual deburring
• Enhance efficiency

Cons:

• Complex structures are not applicable
• Specialized tools are required

Hole Deburring

This method targets the deburring of inner holes. It uses tools to smoothly enter and exit the hole without damaging the surface. Some tools have a tapered tip for creating chamfers. This is a cost-effective and fast solution for multiple pieces.

Pros:

• Quick and affordable
• Multi-pieces with excellent surface finishes.

Cons:

• Only for holes
• Specific tools are required

Brushing

The surface is “cleaned” with a brush similar to sandpaper, but it’s more efficient and can be automated when mounted onto machine tools. This technique is beneficial for parts with complex shapes, such as crankshafts.

Pros:

• Rapid and Economical
• Compatible with complex parts
• Affordable brushes offer automation potential

Cons:

• May need multiple brushes for effectiveness
• For increased efficiency, you will need a tool changer

Electrochemical Deburring

Electrochemical deburring or electropolishing is the best option for small parts that have burrs. This process reverses metal plating by removing material with an electrode, electrical current, and sodium-based electrolyte.

Pros:

• Precision for the most challenging areas
• The deburring process can be used on multiple parts at once
• No heat-affected zones or tool wear

Cons:

• Limitations to small parts
• Custom tools are required and may inadvertently impact non-targeted area

Tumbling

The use of liquids and abrasives in a centrifugal or vibratory barrel can provide an excellent finish, eliminating burrs while avoiding surface damage. This is suitable for plastics and ceramics.

Pros:

• Highly efficient but less aggressive
• Other imperfections are addressed

Cons:

• Special Machinery Needed
• Different mediums are required for different applications

Grinding and rolling

Mechanical deburring by grinding or rolling is a good option for those who want a high-quality finish. It offers flexibility, cost-effectiveness, and high production rates compared to the manual method.

Pros:

• Simple, fast, and flexible
• High production rates and economic viability

Cons:

• Smaller products are generally more suitable.
• This may necessitate additional processing.

Thermal Deburring

The Thermal Energy (TEM) method uses controlled combustion to remove burrs from multiple pieces simultaneously. It relies on a precise mixture of oxygen and fuel, which avoids damaging the parts but effectively removes thin burrs.

Pros:

• Quick and versatile
• Multiple parts can be processed at the same time
• High production rate

Cons:

• Some parts may need protective measures
• The material removed becomes oxide and requires further processing