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In recent years, the use of various types of machine tools, such as electronics, information, and optical machinery, has been aimed at high precision and high functionality, and has been increasingly miniaturized. In order to most effectively utilize the function of the part itself, high-precision deburring technology is very important.
The occurrence of burrs in various machining processes: (a) An example of machining a cavity with a diameter φ 50 μm end mill. At first glance, it seems to be very clean, but in fact there are a few micron-sized tiny burrs on the edges. (b) Glitches produced by grinding. Since this is an electrical product part that is in direct contact with the human body, a 10 μm burr is not allowed to remain. (c) Press parts formed by the press, fine burrs can be observed at all positions, because the burrs fall off during use, which may cause malfunction of the appliance, so it must be removed. (d) Glitches generated during drilling on a thin plate. In addition to burrs generated during cutting, grinding, and shearing, casting, plastic deformation, and laser processing also produce melt-solidified burrs, attached burrs, etc., and burrs are unavoidable in many processes.
In principle, no burrs are produced, but unless an atomic-level processing method is used, other processing methods must produce burrs. Deburring is closely related to the edge processing method. The more advanced the technology and the finer the parts, the greater the influence of the edge quality on its performance.
The countermeasures against burr generation involve three stages: product design, process design and on-site production. The more appropriate the treatment, the more obvious the effect and the lower the cost.
Problems in edge processing at the production site The following problems exist in the edge processing at the production site:
(1) Quality of the edges The burrs remaining on the edges of the parts cannot be completely removed; the edge shape and quality required for the function cannot be achieved; the parts that generate burrs adversely affect the subsequent assembly and the like.
(2) Cost and productivity The manufacturer hopes to achieve deburring automation at the production site, but has to rely on manual deburring due to production problems and the price of the special plane.
(3) Manual removal of burrs can cause safety problems and environmental problems.
Most of the above production site problems are difficult to solve in the follow-up process. Therefore, we must consider how to achieve the required edge quality from the initial stage of product design and process design.
Glitch Control Method (1) Glitch Control in Product Design Process The method of controlling burr in the product design process includes: 1 selecting a processing method that produces less burrs; 2 changing the shape or material of the product.
For parts that require machining, consider choosing other machining methods to control the generation of burrs. For example, since the face and the face intersect, burrs are generated during the cutting process, and a method of reducing the crossing angle or chamfering may be employed. In general, brittle materials are less prone to burrs than materials with high ductility. Therefore, changing materials can be one of the solutions, but it is difficult to implement due to various constraints.
(2) Glitch control in the process design process The method of controlling the burr in the engineering design process includes: 1 changing the process sequence: changing the drilling process sequence, changing the processing machine, etc.; 2 changing the processing method: changing the drilling process Stamping processing, using cutting or overlapping cutting.
(3) Glitch control in on-site machining The method of controlling burrs in on-site machining includes: 1 trying to reduce the cutting resistance; 2 changing the shape of the tool; 3 trying to change the path of the tool.
There are few new ways to remove burrs, almost always using the same principles, such as mechanical, electrical, chemical, thermal and the combination of these principles. The most effective deburring tools and devices must be selected among the above principles based on various factors such as the material, shape, size, and number of the workpiece. The characteristics and application scope of various deburring methods are as follows:
1 magnetic grinding method: the only way to produce gloss and remove burrs, processing speed and uniformity are the issues to be solved.
2 Electrolytic processing method: using SUS phosphoric acid series electrolyte, it can remove burrs but is not good for edge processing; it is suitable for sieves, filters, etc.
3 barrel grinding method: fine granules can be used to make the burrs smaller, but can not be completely removed, the flatness of the grinding block is difficult to maintain; suitable for ordinary stamping parts, eyeglass frames, screws, surgical instruments and the like.
4 chemical burr removal method: burrs may be removed, but the edge quality and dimensional accuracy is difficult to meet; suitable for semiconductor lead frames, screws, stampings, etc.
5 liquid honing method: how to ensure the quality of the surface and edge is a problem, it is possible to solve by selecting suitable abrasive particles; suitable for ordinary stamping parts.
6 Sandblasting method: deformation and edge quality is a problem. It is possible to solve the problem by removing the burrs on the injection needle by selecting suitable abrasive particles. It is suitable for plastic products, cast parts, shaft parts, golf clubs, etc.
7 Water Jet Method: It is feasible to improve the existing water jet deburring technology, but it cannot completely remove the burrs at all; it is suitable for gearbox parts and carburetor.
8 brushing processing method: using soda electrolyte with easy disposal of waste liquid, edge quality and productivity are good, it is necessary to consider rust prevention; suitable for various auto parts, golf clubs, etc.
The above methods have their own strengths and should be carefully distinguished when selecting. Among them, the most commonly used methods of electrolysis and chemical deburring (all need special treatment of waste liquid), if considering environmental protection, it is difficult to call it a good method.
From the past, sharp edges are obtained by electrolytic deburring, and there are important uncertainties in this method, including edge sharpness (edge ​​accuracy, uniformity), shape adaptability (adaptability of three-dimensional shape), and no one. The difficulty of day and night operation in the process of chemical or automated processing, and the impact on the environment. In this way, it is necessary to select various parameter settings and methods that best suit the product requirements.
Technical issues for deburring 1 Digitalization and automation related to surface processing and deburring - digitalization to achieve uniformity and unmanned product characteristics.
2 Visualization of burrs and edges and their image processing, quantitative evaluation and countermeasures - through on-line quantitative evaluation, fast and good edge processing can be performed.
3 Try to use spur-resistant product design (the most suitable processing method according to the choice of parts) - choose the processing method that is not easy to produce burrs as much as possible, and try to make this processing method most suitable for burr removal and reduce the workload of processing edges.
4 Establish a database of surface treatments and deburring – For new and new-shaped parts, it is very laborious to try to find the most suitable method through experimental testing. Building a database can make tedious work easier.
5 Develop new techniques for deburring based on new principles – this is probably the hardest. The burr removal method described above is conventional in principle. The key is to re-examine the edges of the design from all aspects to make the integration between the processes smooth.
Don't say that advanced cutting-edge technology, that is, conventional techniques that can achieve quantification, is also very difficult. It is because of the difficulty, it has not been solved. Deburring technology is part of this conventional technology.
It is true that even the most advanced nanofabrication produces burrs. How to control burrs and processing edges, the success of the most advanced technology in the future, is closely related to how best to integrate with immature technology. Look forward to the joint efforts of the burr processing technicians.
No matter which machining is done, it will produce burrs. The so-called burr-free processing does not mean that no burrs are produced, but that the generated burrs are small and do not affect the function of the product. The size of the burr varies depending on the type of processing, from the case where large burrs are generated during the manufacture of hot forged parts, as well as tiny burrs that are invisible to the naked eye, such as those produced by precision presses or micromachining.