FEATURE INDUSTRIAL CLEANING
AUTOMATED DEBURRING boosts machine shop throughput
With advances in abrasive technology CNC operators can complete surface finishing with other machining operations to speed product completion, improve quality and save costs
O
ne of the more noteworthy advancements in tools for inline
machine deburring, edge radiusing, cleaning and other surface finishing applications is the abrasive nylon brush. For automated applications these are densely bristled brushes composed of abrasive and flexible nylon filaments attached to a machine-mountable base. Each filament contains grit particles that provide machining actions including deburring, cleaning, edge blending and polishing. When configured for CNC or robotic applications, typically thousands of nylon filaments containing the appropriate grit are affixed in clusters to a single base mounted to the machining equipment. Typical applications include deburring,
cleaning and rust removal, preparing surfaces for plating or painting, spot finishing and polishing. They commonly replace grinders, polishing heads, chamfering tools and hand deburring. “The abrasive filaments work like
‘flexible files’ conforming to workpiece contours, wiping and filing across part edges and surfaces to deliver maximum burr removal rates along with an ideal surface finish,” says Eric Sun, founder of Orange Vise Company. A quality abrasive nylon brush is
durable and self-sharpening, providing excellent performance and wear life. Because of linear filament construction, as these brushes come in contact with work surfaces during machining use, filament grit wears off, exposing new cutting particles. Abrasive nylon fibers offer improved
compliancy to the contours of even very complex workpieces, preventing damage while ensuring consistent finishing quality. Using abrasive nylon brushes can eliminate the need to use other tools in automated applications. “This tool is applicable when tumbling
would be required to achieve extensive deburring,” continues Sun. “While tumbling can produce a nice surface finish it can create minor defects on parts because they come into contact with one another. Although it may take an extra minute or two to completely finish workpieces in the machine using the abrasive nylon brush technology, in
14 NOVEMBER 2014 | FACTORY EQUIPMENT
my experience it is usually worth it in terms of quality and costs.” Among a variety of abrasive nylon brush tools, Sun has adopted the NamPower line offered by Brush Research Manufacturing. “We use the Dot style for deburring
highly contoured workpieces with a lot of peaks and valleys,” says Sun. “It is particularly economical for light deburring operations when short cycle times are important.” The Turbine style brush has a more aggressive pattern used mainly for medium and heavy deburring applications. It is better suited to flatter workpieces with fewer contours and can be used to simulate a milled finish without removing any material. Both styles are available in a variety of abrasive types and grit selections to work with materials including metals, super alloys, plastics, advanced composites, metal matrix and ceramics.
CONSISTENT FINISH Available in three diameters and two trim lengths they can be used to automate processes on VMC, HMC, CNC and robotic applications, producing a consistent finish from part to part. Composed of flexible abrasive nylon filaments bonded to a fiber reinforced thermoplastic base NamPower abrasive disc brushes contain a combination of ceramic and silicon carbide filaments. The ceramic abrasive tends to cut a bit coarse and the silicon
NamPower abrasive discs are designed to allow CNC operators to automate the deburring process
carbide acts as a buffer to the cutting action. The end result is deburring and surface finishing in a single operation. These brushes work well with non- ferrous, cast iron, mild steel and ductile iron, stainless and alloy steels, titanium and high nickel alloys. “We’re finding more and more uses for the brushes,” says Sun. “We use the same ones for aluminium, steel, cast iron and stainless steel without having to swap them out very often.” One such application and one of its
primary purposes is for edge blending. Orange Vise utilises deburring tools
including a 45-degree chamfer. Although it doesn’t typically leave a burr, it can when it begins to wear. An employee was required to inspect each part and handle any burrs by hand. Now the company automatically deburrs chamfered holes and edges using the NamPower abrasive disc brush in addition to chamfering with a 45° milling cutter. “With this type of equipment working
into the evenings and weekends, it’s really desirable to get the finishing operations done straight out of the machine,” says Sun. “Some shops running three shifts may still prefer to use their machines producing parts – not deburring. But for many operations it’s more efficient to let the machine do everything online so that the part comes out ready to wash and box for delivery to the customer. That can really make a big difference because you’re using any unutilised machining hours plus you’re automatically producing parts with consistently high quality.” Brush Research is to release products featuring diamond and ceramic impregnated filaments. A series of affordable diamond filament wheel brushes is designed to finish harder materials like ceramic and carbide. Several end brush designs featuring ceramic filament will be available in smaller diameters to provide the benefits of abrasive nylon finishing and small parts and recesses.
Brush Research T: +1 323-261-2193
www.brushresearch.com
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