Metal Workpiece Deburring: Innovative Metal Machining

When workpieces are manufactured, disruptive burrs on bore edges must be removed. If burrs remain, they can not only affect function and aesthetics but also pose a safety risk. Metal products, in particular, must be deburred, but this is also necessary for materials like plastic or wood.

4 Interesting Facts About Deburring Metal Workpieces

1) Increased Safety Through Burr Removal

Removing sharp edges and burrs from the workpiece improves safety for workers and end-users. Additionally, simple and automated processes reduce the risk of injury to employees. Manual processes, on the other hand, pose a significant risk.

2) Improved Quality Through the Right Process

Usually, the most cost-effective deburring method is not the most suitable one. Poor deburring processes can lead to surface damage or dimensional deviations. However, if deburring is carried out carefully, it ensures that the desired tolerances are met. Complex quality controls are thus avoided. It is worthwhile to consult deburring specialists like HEULE.

3) Cost Savings Through Automation

Automated deburring directly on the CNC machine makes subsequent process steps unnecessary, as the workpiece comes off the machine already deburred. This can save costs and reduce production times. Such automated deburring processes are particularly attractive in series production.

More about deburring processes

4) Automated Machining of Complex Geometries

Automated deburring processes also exist for complex geometries such as intersecting bores or challenging materials. Often, custom-adapted solutions ensure process-reliable and precise machining of sharp edges. HEULE offers its customers not only a comprehensive service packages but also individual developments.

More about individual developments

Properties of Metals

Workpieces made of metal, in particular, require special methods to remove burrs. Before we delve into various methods, we would first like to highlight the specific characteristics of different materials.

Aluminum

This relatively soft material produces soft and smeary burrs. These often cause tools to clog during deburring, leading to tedious cleaning processes.

Precision-deburred steel component with a smooth, uniform chamfer created by an automated HEULE tool.

Steel/Stainless Steel

Due to the hardness of the material, deburring steel components is challenging. Significant heat generation often occurs during deburring, which can wear out tools and affect the quality of the workpiece.

Titanium

Titanium is a very strong material that demands high-quality deburring tools for its machining. The high temperatures generated during machining can lead to stress cracks.

Cast Iron

Cast iron parts typically have process-related tolerances that arise during casting. These pose significant challenges during deburring. Processes or tools that can easily compensate for height differences are required.

For example, circular deburring involves following a predefined tool path. Due to tolerances, some areas might not be chamfered at all, or the chamfer might be too small or too large. HEULE's tools with movable blades, however, offer process-reliable solutions, as the blade only begins to deburr upon contact with the bore edge.

Inconel

Inconel is known for its exceptional strength and resistance to high temperatures and corrosion. This leads to rapid wear of deburring tools. Furthermore, Inconel tends to form long chips, which can complicate deburring.

Cleanly deburred hole in a thin metal sheet, showing a burr-free result on both sides.

Sheet Metal

The thickness of the sheet metal, in particular, plays a crucial role in choosing the appropriate process. Different processes are used depending on the sheet metal.

A polished copper component after automated deburring, featuring a smooth and precise edge.

Copper/Brass

These soft materials must be deburred very carefully, as the workpieces can otherwise deform.

Application Examples

A machinist manually deburring a metal part, an inefficient process that HEULE's automated tools replace.

Processes for Deburring Metal Workpieces

In this chapter, we will examine the various processes for machining metal workpieces and cast iron. The different methods vary in their mode of operation, application areas, and effectiveness. The choice of process depends on several factors: size, shape, and material of the workpiece, requirements for the result, and the burrs themselves.

The most common methods are mechanical deburring, electrochemical machining (ECM), thermal energy method (TEM), high-pressure waterjet deburring, brush deburring, manual deburring, deburring with step drills, and blasting with granulates. The individual processes are detailed under the following link.

Overview of Deburring Processes

HEULE precision tool automatically deburring the backside of a metal borehole in a single operation.

Mechanical Deburring Tools from HEULE

HEULE offers a wide range of mechanical deburring tools specifically suited for deburring metal parts. The tools enable final machining of the workpiece directly on the machine. Back-bore machining eliminates further process steps, optimising costs and process times. The automated processes are also characterised by high repeatability.

Deburring

Uniform deburring on both sides in a single operation – without turning the workpiece.

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Chamfering

Economical chamfering of bores, front and back, in a single operation.

More about chamfering

Counterboring

Counterboring of bores without turning the workpiece.

More about counterboring

Bohren mit Entgraten, Fasen oder Senken kombinieren.

Combined Drilling

Economical drilling combined with deburring, chamfering, or counterboring.

More about drilling combined

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Deburring refers to the process of removing burrs that remain on the edges and bores of workpieces after machining (milling, turning, drilling). Burrs are undesirable material residues that affect the safety, functionality, and aesthetics of the workpiece.

To reduce the risk of injury and prevent cuts, it is important to remove burrs and chips carefully. Deburring tools should always be used according to the manufacturer's instructions.

HEULE offers specialised deburring tools such as COFA, DL2, and X-BORES, which are designed for various bore diameters and special applications. HEULE also develops custom-designed tools as needed.

To the Tool Selector

Yes, HEULE offers custom-adapted solutions for burr removal. Either a minor adjustment is made to an existing tool system, or an individual system is developed if there is sufficient potential.

To Custom developments

Various factors influence the choice of the right deburring tool: material, bore diameter, deburring requirements, industry, or even machine conditions. HEULE's goal is to present each customer with the appropriate solution. These can be selected via the Tool Selector, or the sales team is available for your inquiries.