Robotic Deburring: Kemet show how to Deburr and not demur
During most machining operations, components become burred, and sharp edges or material compression occurs. These effect the quality of the part and can create issues with assembly and failure of parts due to break off of material during working life. Removal of burrs is often critical to many of the lapping and polishing processes Kemet develop for customers, to prevent damage to lapping/polishing support materials, to maintain geometry after lapping and extend their life.
Kemet are always monitoring technical developments around the world and have a range of processes to offer a comprehensive deburring solution.
The comprehensive range of precision power hand tool systems, including Nakanishi, Diprofil, and Flexible Drive Systems, with attachments and abrasive consumables suitable for grinding, smoothing, polishing, and deburring, has been expanded to include the full range of Xebec deburring and polishing products. Deburring solutions available also incorporate vibratory deburring/polishing bowls/troughs/media, super centrifuge machines and dry electrolytic polishing processes.
The Xebec products cater for either hand use or for in process, CNC/Robotic use, with tailored tools for the full range of deburring challenges, including after face-milling, end milling and drilling; threading and drilling, and polishing brushes to remove cutter marks on top surfaces, side, inner diameters, and channels. A simple check whether the Xebec brush range is suitable for removing the burr is to see if it can be bent by your fingernail. If they can be bent, then the brushes will work.
Traditionally abrasive loaded nylon brushes have been used for deburring, but Xebec brushes use abrasive ceramic fibre. One single bristle consists of 500 -1,000 ceramic fibres that works as cutting edges, providing excellent cutting ability. This offers a number of features to improve CNC deburring & polishing.
The unique ceramic fibres are the abrasives with a fibre content ratio of more than 80%. Cutting edges that are made up from the tip of each fibre bristle create enormous grinding power, 60 times more than nylon brushes, and this power rapidly removes the burrs.
Due to the structure of the ceramic fibre, new cutting edges are constantly being exposed and the brush maintains a consistent cutting performance right up until the fibres have worn down to the end.
Unlike nylon brushes the ceramic fibres do not deform with use and the Xebec brush maintains its straight shape and does not spread out like a toothbrush even after repeated use. This makes it perfect for CNC deburring and polishing in mass production lines.
In addition to the ceramic brushes, Kemet also offer the Xebec range of Back Burr Cutters specifically for deburring front and back of drilled or tapped holes. These are supplied with a custom made tool path so the cutter cuts into a 3D curved edge with the optimal cutting angle ensuring no secondary burrs are generated. The tool life is dramatically extended by continuously shifting the contact point of the cutting edge. In tests these tools have been proven to cut machining times by up to 90%.
Advice on the most suitable brush for customers’ component geometry, material and challenge is available from Kemet’s team of technical representatives, using Xebec’s knowledge base, garnered from deburring solutions they have provided to companies worldwide from a variety of different sectors, from medical to aerospace, from auto to electronics.