Metal Tumbling & Deburring
Many times, in the metal cutting process, parts are left with small raised edges that can be very sharp. These small pieces of metal that remain attached to the metal parts are known as burrs. In order to get rid of these small, stray pieces of metal that can be dangerous when handling metal parts, we use a deburring process.
The key to creating a metal part without burrs is to not make any burrs in the cutting process, but this is not always possible. It is inevitable that when you are cutting metal, there will be some minor imperfections in the material that cause burrs. Because of this, we must use deburring machines in our metal fabrication process to make sure that we are providing the best quality products for our customers.
Table of Contents
Request A Quote
Types of Metal Tumbling and Debruuing
It would be very time-consuming and laborious to remove metal burrs individually, by hand. That is why we use a barrel tumbler to deburr many small parts at once. Barrel tumbling is excellent at rounding off corners and removing any sharp burrs on parts that have heavy radiuses. Different speeds and amplitudes of vibration are used when deburring different parts, but in general: High speeds and large amplitudes can get the job done by rolling over burrs and mushroom sharp edges.
When using the process of vibratory deburring, it can be compared to that of a filing action. As upward, angular force is applied, metal parts and media are rubbed together creating a cutting action. A vibratory tumbler applies a force 5 to 10 times greater than that of a barrel tumbling machine. This results in a much shorter cycle time as the vibratory tumbler is able to cut the entire load with one pulse. Vibratory deburring can be used on fragile parts because there are no unequal forces acting on the parts.
Inside the Machines
Both Barrel tumbling and vibratory deburring use some form of media to create soft, clean edges on metal parts. The media in our deburring machines may consist of stone, ceramic, or plastic beads. Water is added to the machines to wash away dirt and carry the media. When necessary, chemicals are used to improve the quality of the finished product.
Deburring is the act of removing sharp burrs from large and small parts edges to smooth them down. Tumble Deburring is a procedure used for medium to large, less-fragile stampings as a pretreatment for the next operation. It generates a softened edge on metal components that is safe to handle and promotes the adhesion of plating or other coating systems on the edges. Our vibratory finishing and shot blasting operations benefit greatly from this approach of deburring and cleaning.
Different types of metal Burrs
Deburring can be classified not only by the cutting direction but also by the mechanism by which it is formed. Poissrolloverover, tear, and cut-off is the four different types.
There are two sorts of mechanical rollover burrs and breakout burrs. During metal forming procedures such as drilling, shearing, punching, sawing, and routing, the first and final types of burr are inflicted. The use of the right tools, as well as the proper speed and feed rates, can help to eliminate burrs.
The term “Poisson” comes from the Poisson effect, which refers to the expansion of directions perpendicular to the stress application. When compressive stresses are applied to a material, the edges of the area in contact distort and elongate, forming burrs. As the cutting tool’s tip makes contact with the workpiece, the compressive and shearing forces cause the cut’s edges to distort. Entrance burrs, which occur at the cutting tool’s entry point, are the result of these deformations.
Chips that are bent rather than severed off the cutter’s path are called bent chips. Some material rolls and travels with the cutting tool as it exits the cut. The material folds inwards and along the cut edge toward the feed. The chip does not separate from the portion of the material that is sufficiently ductile. Because the chip or roll becomes thicker as the depth increases, the depth of cut also leads to the production of a roll-over burr.
Tear burrs are sided burrs that arise when a cut item is plastically distorted rather than sheared completely. This is seen in punching techniques, where the contour of the punched hole is left with a sharp, jagged edge. This is the result of material ripping away from the workpiece.
The leftover material as the cut component separates or falls off from the main part causes a cut-off burr. This might be either a good or bad burr. Saw cuts and automatic screw machine parts are the most common places to find cut-off burrs. Burrs of this type can be avoided by adequately supporting both sides of the cut until it is completed.
Slags spatters, and dross are all terms used to describe these types of burrs. Slags are formed when molten metal is hardened through welding, plasma cutting, or laser cutting. Due to residual stresses caused by heating and uncontrolled cooling, slags have different mechanical characteristics than the base metal. Slags may normally be chipped off using a manual power brush, but grinding may be required in some circumstances.
What materials can be used in tumble deburring?
Deburring is done with a variety of materials, including rice and glass beads. However, ceramic, plastic, steel, and organic compounds are the most common media materials used.
Due to its high density, ceramic media can easily grind and polish hard materials such as titanium and steel. Porcelain is used in ceramics to give it a lustrous gloss. Ceramic media’s fundamental drawback is that, despite its durability, it will ultimately break into smaller pieces. If these chips get lodged in small locations or holes on the parts, they can pose a problem.
For softer metals like aluminum, zinc, and brass, plastic media is the recommended media. Low density, high density, and high-performance plastic media are all available. Deburring, flash removal, and burnishing are all done with low-density media. On both ferrous and non-ferrous metals, high density was developed for enhanced cut and stock removal. High-performance media is designed for use in specialized ferrous metal applications.
Steel media works wonders when it comes to cleaning and burnishing steel items. Steel media, depending on its shape, can also be used to deburr steel. Its lifeline is longer than that of the media. Steel media, on the other hand, is more expensive and takes longer to dry.
Walnut shells and corn cob granules are examples of organic media. Organic media, while primarily used to dry parts, can also be utilized to achieve a high-gloss finish. It’s also less costly than most other types of tumbling media.
Now you are well versed with a different type of metal deburring, what material can be used in tumble deburring, But you may be wondering what is used to polish material in the tumble deburring process. Don’t stop here. Scroll below to get the answer to your question
What is used to polish material in the tumble deburring process?
The last process involves polishing the stones using powdered polish (such as cerium oxide or tin oxide), water, and sometimes tiny plastic pellets that cushion the stones as they tumble (to avoid chipping) and uniformly distribute the polish.
How big are metal pieces that can be tumble deburred?
In general, Large metal pieces necessitate the tumble deburring process, Larger pieces give larger components a faster cut and a smoother surface, but they can harm smaller, more delicate parts.
It’s also crucial to choose a media size that won’t get stuck in the component. This blunder might cost you time and put the parts you’re working within jeopardy.
ABT Metals Deburring Services
ABT Metals utilizes vibratory finishing & tumbling services to remove burrs, clean parts, and produce a uniform finish. Our sanders and deburring tools assist with getting your parts completed. We only provide our customers with our best work. All of the parts that come out of our facility will be the highest quality and exceed your expectations. If you have any questions about our deburring services, don’t hesitate to contact us today!