What is a Burr?
Burrs in metal machining refer to the rough and uneven edges on a metal piece. Most burrs form during manufacturing processes because of the tools involved in production. Burrs commonly form during cutting operations on metals. They affect the quality and performance of resulting metal pieces, making it necessary to deburr. Some negative effects of burrs include:
- Reduced safety of sheet metals – sharp and uneven edges on metals make handling hazardous.
- Increased stress during operation – burrs reduce resistance to friction.
- Increased susceptibility to corrosion – caused by the difference in thickness of the materials.
- Lubrication issues
- Difficulty in applying finishing touches, such as electroplating or powder coating.
While manufacturing processes should avoid burr formation, it is an unavoidable side-product of most machining and cutting processes, such as engraving, milling, drilling, laser cutting, blanking, and punching. However, not all processes can result in burr formation. Apart from these processes, skills, and awareness of machine operators, metal material grade, and thickness also contribute to burr formation.
What are the Types of Burrs?
The four main types of burrs resulting from machining processes include:
- Rollover burrs – they are tiny curled metal bits on the surface of machined parts that project up. They represent the most common form of burrs.
- Breakout burrs – unlike rollover burrs, breakout burrs take an upswell shape and appear like they’d break out.
- Poison burrs – these are tiny bits on machined parts that extend sideways.
- Tear burrs – they form due to deformation when the machined material tears. They are common during side milling and punching.
What is Deburring and Why is it Important?
Deburring is ideally the process of removing metal burrs, which affect the quality of machined parts in various ways. Besides being insight, metal burrs negatively affect the quality, safety, and functionality of the metal. Machined parts without burrs and sharp edges lead to safer handling and increase personal safety.
Deburring also helps in reducing liability. Unlike single-belt machines used years ago, modern deburring machines smoothen edges and surfaces. This is especially important for metal fabrication projects, which require unmatched precision to avoid potentially harmful situations.
For instance, small metal flecks can end up in consumable products in the food industry, making them very dangerous. Medical products, such as surgical tools, should also have smooth edges. Rough edges can harm the patient internally. Metal Ready offers high-quality deburring machines that smoothen edges and surfaces.
Deburring Methods and Tools
Interestingly, metal manufacturing industries have over 80 deburring processes. Some require manual labor, while others are completely automated. Below are the most preferred deburring methods for a smooth finish.
1. Manual Deburring
Manual deburring is the most common and economical method of deburring machined parts. It involves using sanders, files, brushes, and other hand held deburring tools for a smooth finish. While it is quick and cost-effective, it heavily relies on manual effort. It also lacks consistency, making it ineffective in situations where tight tolerance is required.
2. Mechanical Deburring
Mechanical deburring methods employ the use of technology to smoothen metal surfaces. While they are not cost-effective upfront, they provide unmatched consistency. Choosing the right tool for the job is the key to quality mechanical deburring. Common mechanical deburring methods include:
- Electrochemical deburring – getting rid of burrs in small metal parts is challenging using other burring methods. Electrochemical burring makes it easy for operators to remove burrs in small and difficult-to-reach areas. This mechanical method uses electrodes to remove burrs.
- Grinding and rolling – you should choose a specific machine for this deburring method. This mechanical method removes burrs and easily produces a high-quality finish.
3. Brushing
Brushing scrubs metal burrs using a specially designed brush. This special brush removes abrasive materials from machined parts using the same principles of manual deburring. However, the brushing process is automated to make deburring efficient and consistent.
Conclusion
Deburring is a common practice in manufacturing processes. However, choosing the appropriate deburring method is important to avoid more damage to the piece. If done properly, deburring creates a perfect finish from your machined parts. Feel free to contact us if you would like more information about deburring machines.
